Methods for transferring discrete articles

ABSTRACT

The present disclosure is directed to a method of transferring discrete articles between a transfer assembly and an apparatus comprising a head. The transfer assembly comprises a frame defining a first rotation axis and a transfer member comprising a transfer surface configured to receive one of the discrete articles. The method comprises rotating the transfer member of the transfer assembly about the first rotation axis at a substantially constant angular velocity, maintaining the transfer surface at a substantially constant minimum distance away from a surface of the head at a point of discrete article transfer, and rotating the head of the apparatus about a second rotation axis at a plurality of angular velocities. A first angular velocity of the head is substantially constant at the point of discrete article transfer.

FIELD

The present disclosure generally relates to methods for transferringdiscrete articles and, more particularly, relates to methods fortransferring discrete articles to or from an apparatus comprising one ormore heads.

BACKGROUND

Absorbent articles, such as taped diapers or pant diapers, for example,may be manufactured by a process where discrete articles, such as achassis of a taped diaper or a pant diaper comprising a topsheet, abacksheet, and an absorbent core, for example, are applied to one ormore moving webs of components, such as webs of front and rear beltportions, for example. To achieve this, a transfer assembly may beprovided that comprises one or more transfer members and a framedefining a rotation axis. The transfer member(s) may orbit about therotation axis. Each of the transfer members may comprise a transfersurface that is configured to engage one or more of the discretearticles. The transfer members may pick up the discrete articles at apick-up location and place the discrete articles at a drop-off locationwithin the orbit. In certain instances, the transfer assembly may rotatethe discrete articles about 90 degrees, or other suitable angles,between the pick-up location and the drop-off location about a secondrotation axis that is perpendicular, or substantially perpendicular, tothe rotation axis. Transfer assemblies that rotate and transfer discretearticles are known in the art as “turn and repitch” units because theunits turn the discrete articles and repitch them (i.e., change thespacing or “pitch” between them) between the pick-up location and thedrop-off location. The repitching capability of these units, however, issomewhat limited and frequent change-outs of the entire transferassemblies, or portions thereof, typically must be done to transferdiscrete articles having different sizes (e.g., different MD widthsand/or different CD lengths). This is owing to the fact that thetransfer members of typical transfer assemblies orbit about the rotationaxis at a constant angular velocity, thereby reducing or eliminating anypitch variation at the drop-off location. Differently sized discretearticles may require different drop off pitches at the drop-offlocation. What is needed are methods for transferring discrete articlesthat overcome the repitching limitations and frequent change-outs ofrelated art discrete article transfer methods.

SUMMARY

The present disclosure provides for transfer assemblies that transferdiscrete articles to or from an apparatus comprising one or more heads.The transfer assemblies may comprise a frame defining a rotation axisand one or more transfer members. Each transfer member is configured toorbit about the rotation axis at a constant, or substantially constant,angular velocity. The transfer members each comprise a transfer surfaceconfigured to receive one or more of the discrete articles. The transfersurface may be flat, substantially flat, or may comprise a portion thatis flat or substantially flat. The transfer assembly may transfer thediscrete articles to and/or from the apparatus comprising the one ormore heads. Stated another way, the apparatus comprising the one or moreheads may be positioned on the input side of the transfer assembly, onthe output side of the transfer assembly, or on both the input andoutput sides of the transfer assembly. The one or more heads of theapparatus rotate about a rotation axis of the apparatus at a variableangular velocity or at a plurality of angular velocities. By rotatingthe heads at a variable angular velocity, a significantly expanded rangeof input or output pitches of the discrete articles are provided by thecombination of the transfer assembly and the apparatus(es) compared toonly using the related art transfer assemblies. By providing such anapparatus(es) in combination with a transfer assembly that rotates itstransfer members at a constant angular velocity, the transfer assemblydoes not need to be changed out as frequently and can run more than onesize of discrete articles because of the increased pitch range that thecombination provides.

In a form, the present disclosure is directed, in part, to a method oftransferring discrete articles between a transfer assembly and anapparatus comprising one or more heads. The transfer assembly maycomprise a frame defining a first rotation axis and at least onetransfer member each comprising a transfer surface configured to receiveone of the discrete articles. The method may comprise rotating the atleast one transfer member of the transfer assembly about the firstrotation axis at a constant, or substantially constant, angularvelocity, maintaining the transfer surface at a substantially constantminimum distance away from a surface of the head at a point or zone ofdiscrete article transfer, and rotating the at least one head of theapparatus about a second rotation axis at a plurality of angularvelocities. A first angular velocity of the head may be constant, orsubstantially constant, at the point or zone of discrete articletransfer. In another form, the present disclosure is directed, in part,to a method of transferring discrete articles between a transferassembly and an apparatus comprising one or more heads. The transferassembly may comprise a frame defining a first rotation axis and atleast one transfer member each comprising a transfer surface configuredto receive one or more of the discrete articles. The method may compriserotating the at least one transfer member of the transfer assembly aboutthe first rotation axis at a constant, or substantially constant,angular velocity and maintaining the at least one transfer surface at aconstant, or substantially constant, minimum distance away from asurface of the at least one head at a point or zone of discrete articletransfer. A tangential velocity of the at least one transfer surface maybe constant, or substantially constant, at the point or zone of discretearticle transfer. The method may further comprise rotating the at leastone head of the apparatus about a second rotation axis at a variableangular velocity. A first angular velocity of the at least one head maybe constant, or substantially constant, at the point or zone of discretearticle transfer. A tangential velocity of the surface of the head maybe substantially the same as the constant, or substantially constant,tangential velocity of the at least one transfer surface at the point orzone of discrete article transfer.

In still another form, the present disclosure is directed, in part, to amethod of transferring discrete articles between a transfer assembly andan apparatus comprising one or more heads. The transfer assembly maycomprise a frame defining a first rotation axis and at least onetransfer member each comprising a transfer surface configured to receiveone of the discrete articles. The transfer surface may be flat,substantially flat, or may comprise a flat, or substantially flat,portion. The method may comprise rotating the at least one transfermember of the transfer assembly about the first rotation axis at aconstant, or substantially constant, angular velocity, maintaining thetransfer surface at a constant, or substantially constant, minimumdistance away from a surface of the at least one head at a point or zoneof discrete article transfer, and rotating the at least one head of theapparatus about a second rotation axis at a variable angular velocity.

In still another form, the present disclosure is directed, in part, to amethod of transferring discrete articles from a transfer assembly to anapparatus comprising one or more heads. The transfer assembly maycomprise a frame defining a first rotation axis and at least onetransfer member each comprising a transfer surface configured to receiveone or more of the discrete articles. The method may comprise rotatingthe at least one transfer member of the transfer assembly about thefirst rotation axis and maintaining the transfer surface at a constant,or substantially constant, minimum distance away from a surface of theat least one head at a point or zone of discrete article transfer. Thetransfer surface may be moved at a first constant, or substantiallyconstant, tangential velocity at the point or zone of discrete articletransfer. The method may further comprise rotating the at least one headof the apparatus about a second rotation axis. The surface of the atleast one head may be moved at a second constant, or substantiallyconstant, tangential velocity at the point or zone of discrete articletransfer. The second, constant, or substantially constant, tangentialvelocity of the head may be greater than the first substantiallyconstant tangential velocity of the transfer surface to tension thediscrete articles being transferred at the point or zone of discretearticle transfer.

In yet another form, the present disclosure is directed, in part, to amethod of transferring discrete articles from a transfer assembly to anapparatus comprising one or more heads. The transfer assembly maycomprise a frame defining a first rotation axis and one or more transfermembers each comprising a transfer surface configured to receive one ofthe discrete articles. The method may comprise rotating the at least onetransfer member of the transfer assembly about the first rotation axisat a constant, or substantially constant, angular velocity andmaintaining the transfer surface at a constant, or substantiallyconstant, minimum distance away from a surface of the at least one headat a point or zone of discrete article transfer. The transfer surfacemay be moved at a first constant, or substantially constant, tangentialvelocity at the point or zone of discrete article transfer. The methodmay further comprise rotating the at least one head of the apparatusabout a second rotation axis at a variable angular velocity. The surfaceof the at least one head may be moved at a second constant, orsubstantially constant, tangential velocity at the point or zone ofdiscrete article transfer. The second constant, or substantiallyconstant, tangential velocity of the head may be greater than the firstconstant, or substantially constant, tangential velocity of the transfersurface.

In yet another form, the present disclosure is directed, in part, to amethod of transferring discrete articles from a transfer assembly to anapparatus comprising one or more heads. The transfer assembly maycomprise a frame defining a first rotation axis and at least onetransfer member each comprising a transfer surface configured to receiveone or more of the discrete articles. The transfer surface may besubstantially flat, flat, or may comprise a flat portion. The method maycomprise rotating the at least one transfer member of the transferassembly about the first rotation axis and maintaining the transfersurface at a constant, or substantially constant, minimum distance awayfrom a surface of the at least one head at a point or zone of discretearticle transfer. The transfer surface may be moved at a first constant,or substantially constant, tangential velocity at the point or zone ofdiscrete article transfer. The method may further comprise rotating theat least one head of the apparatus about a second rotation axis. Thesurface of the at least one head may be moved at a second constant, orsubstantially constant, tangential velocity at the point or zone ofdiscrete article transfer. The second constant, or substantiallyconstant, tangential velocity of the at least one head may be greaterthan the first constant, or substantially constant, tangential velocityof the transfer surface to tension the discrete articles beingtransferred at the point or zone of discrete article transfer.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a front perspective view of a transfer assembly configured totransfer a discrete article from a first apparatus comprising a head toa second apparatus comprising a head in accordance with the presentdisclosure;

FIG. 2 is a perspective view of a pant in accordance with the presentdisclosure;

FIG. 3 is a schematic illustration of an absorbent article capable ofbeing formed into the pant of FIG. 2 in accordance with the presentdisclosure;

FIG. 4 is a front view of the transfer assembly and the apparatusescomprising the heads of FIG. 1 in accordance with the presentdisclosure;

FIG. 5 is a top view of the transfer assembly and the apparatusescomprising the heads of FIG. 1 in accordance with the presentdisclosure;

FIG. 6 is a rear perspective view of the transfer assembly and theapparatuses comprising the heads of FIG. 1 in accordance with thepresent disclosure;

FIG. 7 is a rear view of a portion of the transfer assembly of FIG. 1 inaccordance with the present disclosure;

FIG. 8 is a rear perspective view of a portion of the transfer assemblyof FIG. 1 in accordance with the present disclosure;

FIG. 9 is a simplified, front perspective view of a transfer assemblyand portions of apparatuses comprising heads for transferring discretearticles in accordance with the present disclosure;

FIG. 10 is a rear view of two tracks, a transfer member and a rotationassembly movably engaged with the two tracks, and portions of twoapparatuses comprising heads in accordance with the present disclosure;

FIGS. 10A-10C are rear views of a portion of the transfer assemblyhaving a transfer member and transfer surface, wherein the progressionof movement of the transfer surface relative to a second apparatuscomprising a head is illustrated, in accordance with the presentdisclosure;

FIG. 11 is a side view of a portion of transfer member comprising aflat, or substantially flat, transfer surface in accordance with thepresent disclosure;

FIG. 12 is a front view of the portion of the transfer member of FIG. 11having the flat, or substantially flat, transfer surface in accordancewith the present disclosure;

FIG. 13 is a front perspective view of two tracks, a rotation assembly,the apparatuses comprising heads, and a transfer member in a pick-upzone, with a transfer surface in a first position, in accordance withthe present disclosure;

FIGS. 13A-13C are rear views of a portion of the transfer assemblyhaving a transfer member and transfer surface, wherein the progressionof movement of the transfer surface relative to a first apparatuscomprising a head is illustrated, in accordance with the presentdisclosure;

FIG. 14 is a front view of the two tracks, the rotation assembly, theapparatuses comprising heads, and a transfer member, wherein portions ofthe transfer member are moving from a first position into a secondposition in accordance with the present disclosure;

FIG. 15 is a front perspective view of the two tracks, the rotationassembly, the apparatuses comprising the heads, and the transfer member,wherein a portion of the transfer member is in a drop-off zone in asecond position, in accordance with the present disclosure;

FIGS. 16-18 are perspective views of a transfer member engaged with arotation assembly in accordance with the present disclosure;

FIG. 19 is a cut away perspective view of the rotation assembly and thetransfer member illustrating first and second gears in accordance withthe present disclosure;

FIG. 20 is a cut away side view of the rotation assembly and thetransfer member illustrating the first and second gears in accordancewith the present disclosure;

FIG. 21 is a perspective view of an example apparatus comprising a headin accordance with the present disclosure;

FIG. 22 is a front view of the example apparatus comprising the head ofFIG. 21 in accordance with the present disclosure;

FIG. 23 is a perspective view of another example apparatus comprisingtwo heads in accordance with the present disclosure;

FIG. 24 is a side view of the example apparatus comprising the two headsof FIG. 23 in accordance with the present disclosure;

FIG. 25 is a perspective view of a portion of the apparatus comprisingthe two heads of FIG. 23 in accordance with the present disclosure;

FIG. 26 is a rear view of the portion of the apparatus comprising thetwo heads of FIG. 25 in accordance with the present disclosure;

FIG. 27 is a cross-sectional view of the portion of the apparatuscomprising the two heads taken about line 27-27 of FIG. 25 in accordancewith the present disclosure;

FIG. 28A is a schematic illustration of an example apparatus comprisinga head, wherein the head is being rotated about a rotation axis at afirst angular velocity, AV1, and at a first tangential velocity, TV1 inaccordance with the present disclosure;

FIG. 28B is a schematic illustration of the example apparatus comprisingthe head of FIG. 28A, wherein the head is being rotated about therotation axis at a second angular velocity, AV2, and at a secondtangential velocity, TV2, in accordance with the present disclosure;

FIG. 28C is a schematic illustration of the example apparatus comprisingthe head of FIG. 28A, wherein the head is being rotated at a thirdangular velocity, AV3, and at a third tangential velocity, TV3, inaccordance with the present disclosure;

FIGS. 29A-29C are illustrative examples of a discrete article beingtransferred from a transfer surface of a transfer member of a transferapparatus to a surface of a head of an apparatus, with the angularvelocity, AV1, of the transfer surface being constant, or substantiallyconstant, and with the angular velocity, AV2, of the surface being thesame as or substantially the same as the angular velocity, AV1 of thetransfer surface at the point of discrete article transfer and/or withinthe zone of discrete article transfer in accordance with the presentdisclosure;

FIGS. 30A-30C are illustrative examples of a discrete article beingtransferred from a transfer surface of a transfer member of a transferapparatus to a surface of a head of an apparatus, with the tangentialvelocity, TV1, of the transfer surface being constant, or substantiallyconstant, and with the tangential velocity, TV2, of the surface beingthe same as or substantially the same as the tangential velocity, TV1,of the transfer surface at the point of discrete article transfer and/orwithin the zone of discrete article transfer in accordance with thepresent disclosure;

FIGS. 31A-31C are illustrative examples of a discrete article beingtransferred from a transfer surface of a transfer member of a transferapparatus to a surface of a head of an apparatus, with the tangentialvelocity, TV1, of the transfer surface being constant, or substantiallyconstant, and with the tangential velocity, TV2, of the surface beingconstant, or substantially constant, wherein the constant, orsubstantially constant, tangential velocity, TV2, of the head is greaterthan the constant, or substantially constant, tangential velocity, TV1,of the transfer surface at the point of discrete article transfer and/orwithin the zone of discrete article transfer in accordance with thepresent disclosure;

FIGS. 32A-32C are illustrative examples of a discrete article beingtransferred from a surface of a head of an apparatus to a moving orrotating carrier member in accordance with the present disclosure; and

FIGS. 33A-33C are illustrative examples of a discrete article beingtransferred from a surface of a head of an apparatus to a generallylinear conveyor in accordance with the present disclosure.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the methods fortransferring discrete articles disclosed herein. One or more examples ofthese non-limiting forms are illustrated in the accompanying drawings.Those of ordinary skill in the art will understand that the methods fortransferring discrete articles described herein and illustrated in theaccompanying drawings are non-limiting example forms and that the scopeof the various non-limiting forms of the present disclosure are definedsolely by the claims. The features illustrated or described inconnection with one non-limiting form may be combined with the featuresof other non-limiting forms. Such modifications and variations areintended to be included within the scope of the present disclosure.

The term “absorbent article(s)” refers herein to consumer products whoseprimary function is to absorb and retain bodily exudates and wastes.Absorbent articles as used herein may refer to pants, taped diapers,and/or sanitary napkins (e.g., feminine hygiene products). The term“absorbent articles” also specifically includes adult incontinenceproducts, in any form. In some instances, absorbent articles maycomprise or be formed into pants, taped diapers, or sanitary napkins.The terms “diaper” and “pants” are used herein to refer to absorbentarticles generally worn by infants, children, and/or incontinent personsabout the lower torso.

The term “disposable” is used herein to describe absorbent articleswhich generally are not intended to be laundered or otherwise restoredor reused as an absorbent article (e.g., they are intended to bediscarded after a single use and may also be configured to be recycled,composted, or otherwise disposed of in an environmentally compatiblemanner).

The term “nonwoven” or “nonwoven material” refers herein to a materialmade from continuous (long) filaments (fibers) and/or discontinuous(short) filaments (fibers) by processes such as spunbonding,meltblowing, carding, and the like. Nonwovens do not have a woven orknitted filament pattern.

The term “machine direction” (MD) refers herein to the primary directionof material, web, or article flow through a process. In variousmanufacturing and converting processes, such as a bi-fold process, itmay be possible to have more than one machine direction when an articleis undergoing simultaneous processes. In other words, a manufacturingline may have an overall machine direction, but a material or an articlemay travel in directions other than the overall machine direction as itpasses through various processes along the manufacturing line. Forexample, a discrete article having a trailing end portion and a leadingend portion, each portion being attached to the surface of a differentroll and/or conveyor may travel in two different directionssimultaneously. In this example, both directions of travel may beconsidered the machine direction.

The term “cross direction” (CD) refers herein to a direction that isperpendicular to the machine direction.

The term “taped diaper” refers herein to disposable absorbent articleshaving an initial front waist region and an initial rear waist regionthat are not fastened, pre-fastened, or connected to each other aspackaged, prior to being applied to the wearer. A taped diaper may befolded about its lateral central axis with the interior of one waistregion in surface to surface contact with the interior of the opposingwaist region without fastening or joining the waist regions together.Example taped diapers in various configurations are disclosed in U.S.Pat. Nos. 5,167,897, 5,360,420, 5,599,335, 5,643,588, 5,674,216,5,702,551, 5,968,025, 6,107,537, 6,118,041, 6,153,209, 6,410,129,6,426,444, 6,586,652, 6,627,787, 6,617,016, 6,825,393, and 6,861,571.

The term “pant” refers herein to disposable absorbent articles having acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant, child, or adult wearers. A pant may be configuredwith a continuous or closed waist opening and at least one continuous,closed, leg opening prior to the article being applied to the wearer. Apant may be preformed by various techniques including, but not limitedto, joining together portions of the absorbent article using anyrefastenable and/or permanent closure member (e.g., seams, heat bonds,pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.).A pant may be preformed anywhere along the circumference of theabsorbent article in the waist region (e.g., side fastened or seamed,front waist fastened or seamed, rear waist fastened or seamed). A pantmay be opened about one or both of the side seams and then refastened.Example pants in various configurations are disclosed in U.S. Pat. Nos.5,246,433, 5,569,234, 6,120,487, 6,120,489, 4,940,464, 5,092,861,5,897,545, 5,957,908, and U.S. Patent Publication No. 2003/0233082.

The term “discrete article(s)” refers herein to absorbent articles,pants, taped diapers, sanitary napkins, bandages, medical pads anddressings, and any other suitable articles, in any industry, capable ofbeing transferred using the transfer apparatuses and methods of thepresent disclosure. Discrete articles may also refer herein to portionsof the absorbent articles, pants, taped diapers, sanitary napkins,bandages, medical pads and dressings, and other suitable articles.

The discrete articles may be flexible. In one example, discrete articlesmay refer herein to a chassis of a taped diaper or a pant. The chassismay comprise a topsheet, a backsheet, an optional single or dual layeracquisition system, and an absorbent core disposed between at least aportion of the topsheet and the backsheet. The chassis may also comprisestretched elastic elements such as leg elastics and inner barrier legcuff elastics, for example.

In various forms, referring to FIG. 1, the present disclosure provides,in part, transfer assemblies (e.g., 100) and transfer members associatedwith the transfer assemblies, in combination with one or moreapparatuses 101 and 101′ each comprising one or more heads, fortransferring discrete articles and/or flexible discrete articles. Atransfer assembly and at least one of the apparatuses may be referred toherein as the “overall transfer apparatus.” An apparatus comprising oneor more heads may be positioned at the input side of the transferassembly (on the side of element 104), at the output side of thetransfer assembly (on the side of element 106), or at both the input andoutput sides. The one or more heads of the apparatuses may be rotated atvariable angular velocities about a rotation axis of the apparatusessuch that the apparatuses may provide a greater input pitch range and/ora greater output pitch range to the overall transfer apparatus, as isdescribed in further detail herein. By providing an apparatus at theinput and/or output sides of the transfer assembly, the same transferassembly may be used to transfer an increased size range (e.g., MD andCD sizes) of discrete articles without frequently and costly change-outsof the transfer assemblies. Typically, transfer members of transferassemblies have a constant angular velocity, thereby limiting theirinput and output pitch ranges. By providing an apparatus comprising oneor more heads in combination with the transfer assembly greater inputand output pitch ranges can be achieved at a pick-up location or adrop-off location.

The present disclosure also provides, in part, methods for transferringthe discrete articles using the transfer assemblies and the one or moreapparatuses each comprising one or more heads. A chassis of a pant or ataped diaper, for example, may be picked up by a transfer member of thetransfer assembly at a pick-up location while moving at a first speedand may be transferred to a head of an apparatus. The apparatus may thenplace the chassis onto a moving or rotating carrier member, a linearconveyor, or another head at drop-off location at a second speed that isdifferent than or the same as the first speed. Alternatively, a head ofan apparatus may provide the chassis to a transfer member of thetransfer assembly at the pick-up location at a first speed and thetransfer member may then place the chassis onto a moving or rotatingcarrier member at a drop-off location at a second, different speed.Again alternatively, a head of an apparatus may provide the chassis to atransfer member at the pick-up location. The transfer member may thenplace the discrete article onto a head of another apparatus and the headmay then place the discrete article onto a moving or rotating carriermember, a linear conveyor, other type of conveyor, or another head, at adrop-off location. As discussed above, by providing the apparatus on theinput and/or output sides of the transfer assembly, the input and/oroutput pitch ranges can be significantly increased compared to usingonly a transfer assembly and two moving or rotating carrier members.These increased pitch ranges are at least partially contributable to thevariable angular velocity of the heads of the apparatuses.

The discrete articles may be transferred from the pick-up location(e.g., output of roll 104) to the drop-off location (e.g., input of roll106) by the overall transfer apparatus to change the speed and/or pitchof the discrete articles and/or to turn the discrete articles, forexample. Components, such as webs of front and rear belts or discretefront and rear belts, either of which may be configured to together forma portion of a belt in a pant, for example, may be moving over a movingor rotating carrier member, a linear conveyor, or other conveyor in thedrop-off location. The moving or rotating carrier member or linearconveyor in the drop-off location may have a first portion carrying theweb of front belts and a second portion carrying a web of rear belts. Inother instances, the moving or rotating carrier member or linearconveyor may comprise two separate moving or rotating carrier members orlinear conveyor; one carrying the web of front belts and the othercarrying the web of rear belts. If webs of front and rear belts areprovided on the moving or rotating carrier member or the linearconveyor, the chassis may be placed on the transfer member (either frommoving carrier member 104 or head of the apparatus 101, if present),turned, then transferred to a head of the apparatus 101′. The apparatus101′ may then apply the chassis to the moving or rotating carrier memberor linear conveyor in the drop-off location so as to apply the waistregions of the chassis to the first and second webs of front and rearbelts. A first waist region of the chassis may be applied to the web offirst belts and a second waist region of the chassis may be applied tothe web of second belts to form an intermediate absorbent article thatcan be formed into a pant or a taped diaper, for example. The waistregions of the chassis may be glued to the webs of belts or otherwiseattached to the webs of belts. Further details regarding this exampletransfer are provided herein.

The overall transfer apparatus of the present disclosure may be able toturn the discrete articles intermediate the pick-up location and thedrop-off location for placement onto one or more webs of components ordiscrete components traveling over the moving or rotating carrier memberor linear conveyor (hereafter sometimes referred to as a “moving carriermember”) or onto the moving carrier member without being placed ondiscrete components. In one example, a portion of a transfer member of atransfer assembly may receive a discrete article, such as a taped diaperor pant chassis, for example, from a moving carrier member and turn itbetween a first position and a second position (e.g., a 90 degree turnto the discrete article). Then, the discrete article may be transferredby the transfer member to a head of the apparatus 101′. After which, theapparatus 101′ may apply the discrete article onto webs of front andrear belts traveling on the moving carrier member to form an absorbentarticle that may be formed into a taped diaper or a pant, for example.

As discussed above, the overall transfer apparatuses may also beconfigured to repitch the discrete articles between the pick-up locationand the drop-off location. This “repitching” is changing the machinedirection spacing between midpoints of the discrete articles relative toeach other. In an instance, the machine direction pitch of the discretearticles in the pick-up location may be smaller or larger than themachine direction pitch of the discrete articles in the drop-offlocation. The apparatus (or apparatuses) comprising the head(s) of thepresent disclosure aids in providing an overall transfer apparatus thatmay provide a greater range of input and/or output pitches compared totransfer assemblies used without the apparatus. This is owing to thevariable angular velocity of the heads. In other instances, the pitch ofthe discrete articles may not be changed between the pick-up anddrop-off locations. In various forms, the overall transfer apparatus ofthe present disclosure may not turn the discrete articles between thepick-up and drop-off locations, although they may have the ability to doso. In other instances, the overall transfer apparatuses may not havethe ability to turn the discrete articles during a transfer between thepick-up and drop-off locations.

It is to be appreciated that the methods and apparatuses of the presentdisclosure may also be suitable for any other uses that require transferof a discrete article or a discrete component from a pick-up location toa drop-off location, regardless of the desired speed of the discretearticles at the pick-up location and at the drop-off location, andregardless of whether the discrete articles or discrete components needto be turned and/or repitched. These other uses may comprise variousmanufacturing processes for any product, or intermediate product, in anyindustry.

FIG. 2 illustrates an example of a pant 20 that may be at leastpartially formed or manufactured using the overall transfer apparatusesof the present disclosure. FIG. 3 illustrates an absorbent article 10that can be formed into the pant 20 of FIG. 2. Those of skill in the artwill recognize that FIGS. 2 and 3 are merely examples of one absorbentarticle that may be formed, or at least partially manufactured, usingthe overall transfer apparatuses of the present disclosure. Many otherproducts, including other absorbent articles, pants, taped diapers,sanitary napkins, cleaning pad or substrates, dusting pads orsubstrates, wipes, or portions thereof, may be formed, or at leastpartially manufactured, using the overall transfer apparatuses of thepresent disclosure.

The absorbent article 10 has a longitudinal central axis L1 and alateral central axis L2 (see FIG. 3). The pant 20 has an outer surface22, an inner surface 24 opposed to the outer surface 22, a front waistregion 26, a rear waist region 28, a crotch region 30, and seams 32which join the front waist region 26 and the rear waist region 28 toform two leg openings 34 and a waist opening 36. The seams 32 may bepermanent or refastenable. When referring to “pant 20” herein, it willbe understood that the absorbent article 10, although not yet formedinto the pant 20, may be considered a “pant”. It will be understood thatthe pant 20 is disclosed as an example, but that a taped diaper may alsobe formed from the absorbent article 10 merely by adding fasteningelements and/or landing zones to one or both of the front and rear belts84 and 86. Referring to FIGS. 2 and 3, the pant 20 may comprise anabsorbent chassis 38 to cover a crotch region of a wearer and a belt 40extending transversely about the waist opening 36. The pant 20 may alsooptionally comprise an outer cover layer 42 to cover the chassis 38. Thebelt 40 may define the waist opening 36 in the pant 20. The belt 40, thechassis 38, and/or the outer cover layer 42 may jointly define the legopenings 34. In some circumstances, the pant 20 may have a patch sheet44 printed with a graphic 46 thereon, which may be disposed in the frontwaist region 26, the rear waist region 28, or any other suitable portionof the pant 20. The belt 40 may be formed from a front belt 84 in thefront waist region 26 and a rear belt 86 in the rear waist region 28.The front belt 84 may form a front waist edge 35 in the front waistregion 26 and the rear belt 86 may form a rear waist edge 37 in the rearwaist region 28. The front and rear waist edges 35 and 37 may belaterally opposed about the lateral central axis L2. The belt 40 mayform a portion of an outer surface 22 or an inner surface 24 of the pant20. In other instances, the belt 40, or portions thereof, may bedisposed intermediate other layers of the chassis 38, such as a topsheetand a backsheet, for example.

The absorbent chassis 38 may absorb and contain body exudates or wastesdisposed on the chassis 38. Referring to FIG. 3, the chassis 38 may havea generally rectangular shape having left and right longitudinallyextending side edges 48 (hereinafter may be referred to as “longitudinalside edge”) and front and rear laterally extending end edges 50(hereinafter may be referred to as “lateral end edge”). The chassis mayalso have any other suitable shape, such as an hourglass shape. Thechassis 38 may also comprise waist panels (i.e., a front waist panel 52positioned in the front waist region 26 and a rear waist panel 54positioned in the rear waist region 28) and a crotch panel 56 in thecrotch region 30 between the front and rear waist panels 52, 54.

The pant 20 may comprise front and rear belts 84 and 86 intended toencircle at least a portion of the waist of the wearer. The front andrear belts 84 and 86 together form at least a portion of, or all of, thebelt 40 when joined. The front and rear belts 84 and 86 may be connectedby the chassis 38 forming the crotch region 30 of the pant 20. The frontand rear belts 84 and 86 may each be formed from a first belt layer 82possibly forming a portion of the outer surface 22 of the pant 20 and asecond belt layer 83 possibly forming a portion of the inner surface 24of the pant 20. The first and second belt layers 82 and 83 may becomprised of any known materials. Various suitable materials maycomprise films, plastic films, apertured plastic films, woven ornonwoven webs of natural materials (e.g., wood or cotton fibers),synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers), or a combination of naturaland/or synthetic fibers, stretchable nonwovens, or coated woven ornonwoven webs. The belt 40 may comprise an inner hydrophobic, nonwovenmaterial and an outer hydrophobic, nonwoven material. The front and rearbelts 84 and 86 may also comprise a plurality of elastic elements 85disposed at least partially between the first and second belt layers 82and 83 thereof and attached to at least one of the first and second beltlayers 82 and 83 using adhesives or bonding, for example. The elasticelements 85 may comprise one or more elastic strands, elastic materials,elastomeric films, elastomeric ribbons, elastomeric nonwovens,elastomeric filaments, elastomeric adhesives, elastomeric foams, scrims,or combinations thereof

The chassis 38 of the pant 20 may comprise a portion of the outersurface 22, a backsheet 60, a portion of the inner surface 24, atopsheet 58, and an absorbent core 62 disposed between at least aportion of the topsheet 58 and the backsheet 60. In addition, thechassis 38 may comprise elasticized barrier leg cuffs 64 disposed at oradjacent the side edges 48 of the chassis 38. The barrier leg cuffs 64may provide improved containment of liquids and other body exudates orwastes in the crotch region 30 and may comprise a single layer ofmaterial which may be folded to form a barrier leg cuff having twolayers. The barrier leg cuffs 64 may extend from the side of the chassis38 at or adjacent the longitudinal side edge 48 toward the longitudinalcentral axis L1. The barrier leg cuffs 64 may be folded along thefolding lines 66 back toward the longitudinal side edges 48. The frontand rear belts 84 and 86 may overlap at least a portion of the chassis38 and one or both of the front and rear belts 84 and 86 may be disposedon the outer surface 22 of the chassis 38, on the inner surface 24 ofthe chassis 38, or disposed intermediate various portions of the chassis38.

A portion of, or the whole of, the chassis 38 may be made extensible toa degree greater than the inherent extensibility of the material ormaterials from which the chassis 38 is made, e.g., the backsheet 60. Theadditional extensibility may be desirable in order to allow the chassis38 to conform to the body of a wearer during movement by the wearer andor to provide adequate body coverage. The additional extensibility mayalso be desirable, for example, in order to allow the user of a pantincluding the chassis 38 having a particular size before extension toextend the front waist region 26, the rear waist region 28, or both ofthe waist regions of the chassis 38 to provide additional body coveragefor wearers of differing size, i.e., to tailor the pant to theindividual wearer. Such extension of the waist region or regions maygive the chassis 38 a generally hourglass shape, so long as the crotchregion 30 is extended to a relatively lesser degree than the waistregion or regions, and may impart a tailored appearance to the pant 20when it is donned or worn. In addition, the additional extensibility maybe desirable in order to minimize the cost of the pant 20. For example,an amount of material that would otherwise be sufficient only to make arelatively smaller pant lacking this extensibility may be used to makean article capable of being extended to adequately cover a wearer thatis larger than the unextended smaller pant would fit.

A portion of the chassis 38, for example, a portion of the chassis 38 inone or both of the waist regions 26 and 28 may be made laterallyextensible to a maximum extensibility greater than a maximumextensibility of another portion of the chassis 38 in the crotch region30 such that a lateral extension of each of the portions to its maximumextensibility imparts an hourglass shape to the chassis 38. The portionof the chassis 38 underlying, overlying, and/or immediately adjacent oneor both of the front and rear extensible belts 84 and 86 may be madelaterally extensible to a maximum extensibility greater than a maximumextensibility of another portion of the chassis 38, for example thecrotch region 30, such that a lateral extension of each of the portionsto its maximum extensibility facilitates application of the pant 20 ontothe body of a wearer by enabling the waist regions 26 and 28 to beextended to fit over the wearer's hips and in addition, opening andorienting the leg openings enabling the wearer to place the legs throughthe openings more effectively.

The liquid pervious topsheet 58 may be positioned adjacent thebody-facing surface of the absorbent core 62 and may be joined theretoand/or to the backsheet 60 by any attachment methods known to those ofskill in the art. The liquid impervious backsheet 60 may generally bethat portion of the pant 20 positioned adjacent the garment-facingsurface of the absorbent core 62 and may prevent, or at least inhibit,the bodily exudates and wastes absorbed and contained in the absorbentcore 62 from soiling garments that may contact the outer surface 22 ofthe pant 20.

The topsheet 58, the backsheet 60, and the absorbent core 62 may bemanufactured of any known materials. Suitable topsheet materials maycomprise porous foams; reticulated foams; apertured plastic films; orwoven or nonwoven webs of natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyester or polypropylene fibers), or acombination of natural and synthetic fibers. Suitable backsheetmaterials may include breathable materials that permit vapors to escapefrom the pant 20 while still preventing, or at least inhibiting, bodilyexudates or wastes from passing through the backsheet 60. Such materialsmay include nonwoven materials, woven materials, films, and/or laminatescomprising a combination of one or more of these materials. In oneembodiment, the backsheet 60 may be a film and nonwoven laminate,wherein the nonwoven of the laminate forms the outer cover layer 42.

A suitable absorbent core 62 for use in the pant 20 may comprise anyabsorbent material which is generally compressible, conformable,non-irritating to the wearer's skin, and capable of absorbing andretaining liquids such as urine and other certain body exudates.Absorbent material may comprise a superabsorbent material, a cellulosicmaterial, or combinations thereof. In some instances, the absorbent coremay comprise one or more adhesives and a superabsorbent material and maybe free of, or at least mostly free of, a cellulosic material. Inaddition, the configuration and construction of the absorbent core 62may also be varied (e.g., the absorbent core(s) or other absorbentstructure(s) may have varying caliper zones, hydrophilic gradient(s), asuperabsorbent gradient(s), or lower average density and lower averagebasis weight acquisition zones; or may comprise one or more layers orstructures). In some forms, the absorbent core 62 may comprise a fluidacquisition component, a fluid distribution component, and/or a fluidstorage component. An example of a suitable absorbent core having afluid acquisition component, a fluid distribution component, and a fluidstorage component is described in U.S. Pat. No. 6,590,136.

The outer cover layer 42 may be disposed on the outer surface 22 of thepant 20 and may cover the crotch panel 56 of the absorbent chassis 38.The outer cover layer 42 may extend into and cover the front waist panel52 and the rear waist panel 54 of the chassis 38. The outer cover layer42 may form a portion of the backsheet 60 and/or the chassis 38. In aform, the outer cover layer 42 may be directly joined to and cover aportion of, or all of, the liquid impervious backsheet 60 of the chassis38. The outer cover layer 42 may be disposed between the front and rearbelts 84 and 86.

The outer cover layer 42 may comprise a material separate from the firstand second belt layers 82 and 83 forming the belts 84 and 86. The outercover layer 42 may comprise two or more layers of materials of any knownmaterials including the materials used for the first and second beltlayers 82 and 83. The outer cover layer 42 may comprise a single layerof a nonwoven web of synthetic fibers. The outer cover layer 42 maycomprise a single layer of hydrophobic, non-stretchable nonwovenmaterial. In some instances, the outer cover layer 42 may comprise afilm, a foam, a nonwoven, a woven material, or the like and/orcombinations thereof such as a laminate of a film and a nonwoven.

The belt 40 may be at least partially formed, or fully formed, when thefront and rear belts 84 and 86 are permanently or refastenablyconnecting together to form the seams 32. Any suitable seams may beformed, as known to those of skill in the art. The belt 40 may bering-like and elastic. The ring-like elastic belt 40 may extend aboutthe waist opening 36 of the pant 20 and act to dynamically createfitment forces and to distribute the forces dynamically generated duringwear.

Referring to FIGS. 1 and 4-6, an overall transfer apparatus comprising atransfer assembly 100 and at least one apparatus 101 or 101′ comprisingat least one head 105 or 105′ is illustrated. As explained above, anapparatus may be provided on the input and output sides of the transferassembly 100 or may only be provided on the input side or on the outputside of the transfer assembly 100. An apparatus on the input side of thetransfer assembly is labeled 101 and an apparatus on the output side islabeled 101′ (with its various components also being numbered withprimes). The apparatus 101 may be the same or different than theapparatus 101′. The differences may be in size, shape, and/or speed, forexample. The overall transfer assembly is configured to transferdiscrete articles from a pick-up location to a drop-off location, asexplained herein. FIG. 1 is a front perspective view of the overalltransfer apparatus comprising the transfer assembly 100, the apparatus101, and the apparatus 101′. FIG. 4 is a front view of the overalltransfer apparatus of FIG. 1. FIG. 5 is a top view of the overalltransfer apparatus of FIG. 1. FIG. 6 is a rear perspective view of theoverall transfer apparatus of FIG. 1. The overall transfer apparatus maytransfer discrete articles 102 from a first moving carrier member 104 toa second moving carrier member 106. The moving carrier members 104 and106 from and to which the discrete articles 102 may be transferred maybe rolls, drums, curved conveyors, linear conveyors, and/or discreteheads following a curvilinear path, for example. The moving carriermembers may be rotating carrier members, such as rolls or cylindricalrolls. The output side of the first moving carrier member 104 mayrepresent the pick-up location and the input side of the second movingcarrier member 106 may represent the drop-off location in certaininstances. An apparatus 101 may be provided intermediate the transferassembly 100 and the first moving carrier member 104, and likewise, anapparatus 101′ may be provided intermediate the transfer assembly 100and the second moving carrier member 106. The first and second movingcarrier members 104 and 106 may be moving at a different surfacevelocity or at the same surface velocity. Surfaces of the first andsecond moving carrier members 104 and 106 may have different or the sametangential velocities. Typically, surfaces of the first and secondmoving carrier members 104 and 106 have constant, or substantiallyconstant, tangential velocities, but the tangential velocities may alsobe variable in certain instances. A transfer member 112 of the transferassembly 100 or the head 105 of the apparatus 101 (if the apparatus isprovided on the input side of the transfer assembly 100) may pick up thediscrete article 102 at a first velocity, V1, from the first movingcarrier member 104. The transfer member 112 will then convey thediscrete article 102 to the output side of the transfer assembly 100.Next, the transfer member 112 or the head 105′ of the apparatus 101′ (ifthe apparatus is provided on the output side) may apply the discretearticle 102 at a second velocity, V2, to the second moving carriermember 106. The first velocity, V1, and the second velocity, V2, at thepoint or zone of discrete article transfer to and from the first andsecond moving carrier members 104 and 106 may be tangential or linearvelocities.

A continuous web of articles 108 may be fed on a roll or other conveyingmechanism toward the first moving carrier member 104 and, optionally,the apparatus 101. Once a portion of the web of discrete articles 108long enough to form a discrete article 102 is engaged with the firstmoving carrier member 104, is engaged with a portion of a transfermember 112 of the transfer assembly 100, or optionally, is engaged witha portion of a head 105 of the apparatus 101, a knife integral to thefirst moving carrier member 104 may cut the web 108 into discretearticles 102 against an anvil roll 114. The knife may be a flex knife, adie cutter, a shear knife, or any other suitable knife or cutting deviceor mechanism. Knife and anvil roll technology is generally known in theart. In other instances, previously cut discrete articles 102 may be fedon a conveyor toward the first moving carrier member 104. In someinstances, discrete articles 102 may be engaged directly with the head105 of the apparatus 101 directly without the moving carrier member 104and anvil roll 114 being present.

Portions of the transfer members 112 of the present disclosure may alsoturn between a first position 116 and at least a second position 118when transferring the discrete articles 102 from an input side of thetransfer assembly 100 to an output side of the transfer assembly 100. Asa result, the discrete articles 102 may be turned between a firstposition 116 and a second position 118. The portions of the transfermembers 112 may be turned using rotation assemblies engaged with aportion of each transfer member 112, as described in further detailbelow. The discrete articles 102 may be turned between about 30 degreesand about 180 degrees, between about 40 degrees and about 150 degrees,between about 60 degrees and about 120 degrees, between about 75 degreesand about 105 degrees, about 45 degrees (e.g., +/−5 degrees), about 90degrees (e.g., +/−5 degrees), 45 degrees, 90 degrees, about 180 degrees(e.g., +/−5 degrees), or 180 degrees, specifically reciting each 0.5degree increment within the above-recited ranges and all ranges formedtherein or thereby. Optionally, the discrete articles 102 may also notbe turned at all and the transfer assembly may be used for conveyingand/or repitching the discrete articles 102 without turning them.

Again referring to FIGS. 1 and 4-6, continuous webs of components 120may be moving towards, over, and away from the second moving carriermember 106 on a roller, conveyor, or other mechanism. In one example,these webs of components 120 may be front belts 124 and rear belts 126,although in other examples, the webs of components 120 may be variousother components or even discrete components that have been previouslycut from a continuous web. An adhesive may be applied to the webs ofcomponents 120 or discrete components using adhesive dispensers 128. Theadhesive dispensers 128 are optional in some circumstances. The adhesivemay be applied to portions of the webs of components 120 prior to thoseportions being moved over the second moving carrier member 106. As aresult, a discrete article 102 being transferred to the second movingcarrier member 106, by either a transfer member 112 or a head 105′ ofthe apparatus 101′, may be adhesively attached to the webs of components120 when transferred onto the second moving carrier member 106. In oneexample, the discrete article 102 may be a chassis 38 and the frontwaist panel 52 of the chassis 38 may be adhesively attached to thecontinuous web of front belts 124 and the rear waist panel 54 of thechassis 38 may be adhesively attached to the continuous web of rearbelts 126. This may form a web of absorbent articles. The web ofabsorbent articles may then be cut or separated into discrete absorbentarticles, such as the absorbent article 10 of FIG. 2.

Referring to FIGS. 1 and 4-10, the transfer assembly 100 may comprise aframe 130 defining a rotation axis 132 and a track 134 (also referred toherein as a first track or the outer track) having a circumferentialshape surrounding the rotation axis 132. FIG. 7 is a partial rearperspective cross-sectional view of the transfer assembly 100 and FIG. 8is a partial rear perspective cross-sectional view of the transferassembly 100. In both of FIGS. 7 and 8, the frame 130 and various othercomponents have been removed to more clearly illustrate variousfeatures. FIG. 9 is a front perspective view of the transfer assembly100 with multiple transfer members 112 removed for clarity inillustration. FIG. 10 is a rear view of portions of the transferassembly 100 illustrating the track 134, the transfer member 112, andother components for clarity. The apparatuses 101 and 101′ are alsoillustrated in FIGS. 1, 4-6, 9, and 10. The distance between therotation axis 132 and various points on the track 134 may vary. Thetrack 134 may be a cam track. The track 134 may comprise one or moreseparation points 135 in the event the track 134 needs to bedisassembled for maintenance or other reasons. The transfer assembly 100may comprise one or more transfer members 112 movably, rollably, and/orslidably engaged with the track 134. Each transfer member 112 maycomprise a transfer surface 136 on an end of the transfer member 112most distal from the rotation axis 132. The transfer surface 136 may beconfigured to receive one or more of the discrete articles 102. Thetransfer surfaces 136 of the transfer members 112 may be configured toretain the discrete articles 102 thereto using a fluid pressure, such asvacuum, magnets, or an adhesive, for example. The transfer assembly 100may also comprise a wheel 138 supported by the frame 130 and configuredto rotate about the rotation axis 132. The wheel 138 may or may not beround about its perimeter. The wheel 138 may be engaged with portions ofthe transfer members 112 such that as the wheel 138 rotates about therotation axis 132, the transfer members 112 circumnavigate about a pathabout the rotation axis 132 in correspondence with the track 134. Theshape of the track 134 may cause the transfer members 112 to moveradially inwardly and radially outwardly relative to the rotation axis132 while the transfer surfaces 136 are maintained a constant or asubstantially constant distance or minimum distance away from the firstand second moving carrier members 104 and 106 or surfaces of the heads105 and 105′ of the apparatuses 101 and 101′ at the point or zone ofdiscrete article transfer onto and off of the transfer surfaces 136. Thesubstantially constant minimum distance or minimum distance may varytypically from 0-6 mm or may have a tolerance of typically +/−0.1 to 1mm, although a wide range of targets are achievable. In an instance, theminimum distance may be constant, then not constant, then constant againat the point or zone of discrete article transfer as the transfersurface 136 is moved past the point or zone of discrete articletransfer. Such a profile may be employed if, for instance, it is desiredto only maintain the substantially constant gap at the leading and/ortrailing edge of the discrete article transfer. The profile may also beadjusted to account for thickness variations in the discrete articlebeing transferred. In some cases, the gap or minimum distance may beprofiled to be larger in the region with the absorbent core, forexample.

Referring again to FIGS. 1 and 4-10, the frame 130 may be mounted to abase or stand 140 for the transfer assembly 100. The apparatuses 101 and101′ may also be mounted to a base or stand. The track 134 may be formedwith or in the frame 130 or be mounted to the frame 130. The track 134may be a projection that extends from a plane of the frame 130 or may bea groove (not illustrated) defined in the frame 130. The track 134 mayhave a constant, or substantially constant, width, or a varying width,regardless of whether it is a projection or a groove. In the event thetrack 134 is a groove, a follower member 142 extending from each of theone or more transfer members 112 may be movably, slidably, and/orrollably engaged with the groove. The follower member 142 may be biasedtoward the track 134. In the event the track 134 is a projection asillustrated, a follower member 142 extending from each of the one ormore transfer members 112, or portions thereof, may be movably,slidably, and/or rollably engaged with a surface of the projection thatextends generally perpendicular to a front planer surface of the frame130 from which the projection extends. In an instance, when the track134 is a projection, two or more follower members 142 may extend fromeach transfer member 112, or portions thereof, such that one followermember 142 engages a first surface 144 of the projection and anotherfollower member 142 engages the opposite surface 146 of the projection.The follower members 142 may be rollers or cam followers that slide orroll about the track 134 as the transfer member 112 circumnavigatesabout a path around the rotation axis 132. The follower members 142 maycomprise materials such as metals, plastics, and/or polymers, forexample, or coatings thereof, to permit rolling or sliding movementbetween the follower members 142 and the track 134.

In the event that the track 134 is a groove, the follower members 142may comprise two stacked concentric cylindrical cam followers, eachfollowing one side of the groove. This may constrain the cam followersto rotate in one direction and eliminate, or at least inhibit, the issueof cam follower reversal as with a single cam follower following agroove. The stacked cam followers may also be configured witheccentricity between the axes of their rotation. Adjusting the eccentricmay adjust the clearance between the cam groove and the cam followers.An elastic element, such as a spring or pneumatic cylinder, for example,may also be used to keep the cam follower loaded against one surface ofthe groove. This has the potential to only use one surface of thegroove.

In the event that the track 134 is a projection, the follower members142 may comprise two conjugate cylindrical follower members on each sideof the track projection 134. This arrangement may naturally cause eachfollower member to rotate in one direction. The axis of rotation of oneof the follower members may be adjusted to control the clearance betweenthe follower members and the track projection 134. A single followermember may be employed in conjunction with an elastic or inertial forceto keep the follower member in contact with the track projection 134.The follower member may be spring loaded or loaded by pneumaticcylinder, for example.

Referring to FIGS. 16-18 for clarity, the transfer members 112 maycomprise a fluid manifold attached to or formed with a base 141 and thefollower members 142 may be mounted, or rotatably mounted, to the base141. The base 141 may be slidably or movably engaged with a plate 155such that the transfer members 112 may be moved radially relative to thewheel 138 and the plate 155 by the track 134. The plate 155 may be usedto mount portions of the transfer members 112 and portions of therotation assembly (as described below) to projections 156 on the wheel138, as described in further detail herein.

Referring to FIGS. 1 and 4-10, the wheel 138 may be engaged with theframe 130 such that the wheel 138 is permitted to rotate relative to theframe 130 about the rotation axis 132. The frame 130 may locate bearingsthat support the drive shaft 148 and/or the wheel 138. This permitsrotation of wheel 138 and the drive shaft 148 about the first rotationaxis 132. This also locates the axial position of the wheel 138 and thedrive shaft 148. The first rotation axis 132 may be located generallycentrally, although not necessarily at the midpoint of the track 134,within the circumference of the track 134. A drive shaft 148 that has arotation axis common to the rotation axis 132 may be driven by one ormore actuators 150 through the use of a drive belt or chain 152, forexample. The drive shaft 148 may be engaged with the wheel 138 to causethe wheel 138 to rotate. Other methods of rotating the drive shaft 148will be envisioned by those of skill in the art and will not bediscussed in detail for brevity. The one or more actuators 150 may causethe drive shaft 148 to rotate in either the clockwise orcounter-clockwise direction. The drive shaft 148 may rotate in eitherdirection and at any speed about the rotation axis 132 to drive orrotate the wheel 138. The wheel 138 may rotate in a direction generallyparallel with the plane of the frame 130 from which the track 134extends or is defined in. The wheel 138 may be fixedly attached to thedrive shaft 148 such that upon activation of the one or more actuators150, the drive shaft 148 and, thereby, the wheel 138 may rotate.

The wheel 138 may have one or more recesses 154 defined in a perimeterthereof. Fluid conduits and/or other components may extend through therecesses 154 to portions of the transfer members 112. Also, by providingthe recesses 154 in the wheel 138, the wheel 138 may be lighter and haveless rotational inertia.

Referring again to FIGS. 1 and 4-10, the wheel 138 may be engaged withone or more of the transfer members 112 through the use of the plate155. The wheel 138 may have projections 156 extending therefrom in adirection toward the frame 130. Portions of the plate 155 extendingintermediate a portion of the transfer member 112 and a torquetransmitting assembly (as discussed below), for example, may be mountedto the projections 156 on the wheel 138 to provide support to therotating assembly which includes the transfer member 112. The plate 155may be movably engaged with the base 141 as described in greater detailherein. Portions of the transfer members 112 may also be engaged withshafts or shaft assemblies comprising a spline, for example, to allowthe transfer members 112 to be movable in radial directions relative tothe first rotation axis 132. The shaft or shaft assemblies may alsoallow portions of the transfer members 112 to be turned relative to thewheel 138 about a second rotation axis 164 that may be positionedgenerally perpendicular, or transverse, to first rotation axis 132. Theshaft or shaft assemblies and the transfer members 112 may rotate withthe wheel 138. Transfer members 112 may have a constant relative angularposition about the first rotation axis 132 and may share the sameangular velocity about the first rotation axis 132. Stated another way,the transfer members 112 may orbit about the rotation axis 132 at aconstant angular velocity or a substantially constant angular velocity.

The wheel 138 may be engaged with one to sixteen or more transfermembers 112, for example. All or some of the transfer members 112 may beused to transfer discrete articles 102 in various manufacturingoperations. In some instances, every other, or every third, transfermember 112 may be used to transfer discrete articles 102 in a particularmanufacturing operation, for example.

Referring to FIGS. 7, 8, 10, and 16, the one or more follower members142 may extend from the base 141 or other portion of the transfermembers 112 such that they may engage the track 134 and move thetransfer members 112 radially. The follower members 142 may be attachedto portions of the transfer members 112 or may be formed with thetransfer members 112. The “transfer members 112” may refer to not onlythe portion comprising the transfer surface 136 but all of the radiallymovable assembly at the second end 204 of the shaft or shaft assembly200. Radially moving assemblies comprise the fluid manifold, the splinereceiving member, the base 141, the follower members 142, the housing,and the transfer surface 136, for example. Some of these components arediscussed in more detail below. The shaft, the spline, and the secondend of the shaft (as are all discussed below) may not be radiallymoving. In certain instances, more than two follower members 142 may bedesired on a particular track 134 or if more than one track 134 isprovided on the frame 130. In an example, two tracks (not illustrated)for the follower members 142 may be provided on a frame and one or morefollower members may be movably engaged with each of the tracks. Thefollower members 142 being movably engaged with the track 134 causes thetransfer members 112 to circumnavigate about a path about the rotationaxis 132 in correspondence with the track 134.

The shape of the track 134 may be such that it causes the followermembers 142 and, thereby, the transfer members 112, and the transfersurfaces 136 of the transfer members 112, to be moved radially inwardlyand outwardly when the transfer members 112 are rotating about the pathof the rotation axis 132 in correspondence with the track 134. This pathcan be seen in FIGS. 7, 8, and 10, for example. The path may be said tobe about the rotation axis 132. The track 134 may comprise a firstprojection 158 extending radially outwardly from the rotation axis 132proximate to the first moving carrier member 104 and a second projection160 extending radially outwardly from the rotation axis 132 proximate tothe second carrier member 106. This radial extension of the projections158 and 160 is discussed with reference to a non-projection portion 162of the track 134. The projections 158 and 160 may have any suitableshape which generally extends radially outwardly from the rotation axis132. The shape of the projections 158 and 160, among other things, maydictate the tangential velocity of a portion of the transfer surface 136at the point or zone of discrete article transfer from or to one of themoving carrier members 104 and 106 or from or to one of the heads 105and 105′ of the apparatuses 101 and 101′. The shape of the projections158 and 160 may also contribute to or cause the gap between the transfersurfaces 136 and surfaces of the first and second moving carrier members104 and 106 or the surfaces of the heads 105 and 105′ of the apparatuses101 and 101′ to remain constant or substantially constant at the pointor zone of discrete article transfer. These projections 158 and 160 maybe positioned at any locations on the track 134 that are proximate to anincoming first moving carrier member 104 or incoming head 105 or anoutgoing moving second carrier member 106 or an outgoing head 105′. Thetrack 134 may only have one projection 158 or 160 positioned proximateto one of the moving carrier members 104 and 106 or one of the heads 105and 105′. The first projection 158 may be generally across the track 134from the second projection 160 or otherwise situated relative to thesecond projection 160 depending on the positioning of the incoming firstmoving carrier member 104 or incoming head 105 and the outgoing secondmoving carrier member 106 or the outgoing head 105′. The radius of thetrack 134 relative to the rotation axis 132 may increase and decreaseabout the track 134, even in the non-projection portions 162 of thetrack 134. In an instance, the radius of the track 134 may increase atleast when portions of the transfer members 112 are partially rotatedbetween the first position 116 and the second position 118 to allow twoadjacently positioned transfer surfaces of the transfer members 112 toclear each other (i.e., not contact each other) during rotation of thetransfer members 112 about the second rotation axis 164. The increasedradius of the track 134 at these locations forces the transfer members112 radially outwardly relative to the rotation axis 132, therebyproviding adequate clearance of a first transfer surface 136 and anadjacent second transfer surface 136 to rotate between the firstposition 116 and the second position 118. The second rotation axis 164may be perpendicular, substantially perpendicular, or transverse to therotation axis 132. In other instances, the rotation axis 132 may extendin a first direction and the second rotation axis 164 may extend in asecond, different direction. The second, different direction may beparallel or substantially parallel (e.g., +/−0.5 to fifteen degrees) toa plane of the frame 130 from which the rotation axis 132 extends,wherein the plane extends generally perpendicular to the rotation axis132. The rotation of the portions of the transfer members 112 and anexample rotation assembly configured to accomplish this rotation will bediscussed in further detail below.

The track 134 may not increase the radial distance of the transfermembers 112 from the rotation axis 132 during movement of the transfersurfaces 136 between a first position and a second position. In such aninstance, the transfer surfaces 136 may be shaped (e.g., ovate, round)or spaced such that they can be turned between the first position andthe second position without contacting each other.

Referring to FIGS. 1 and 4-12, the transfer members 112 may eachcomprise the transfer surface 136 on the distal most portion thereofrelative to the rotation axis 132, as referenced above. The transfersurface 136 may be flat, substantially flat, or may comprise one or moreflat portions in one or more directions. FIG. 11 illustrates the flat,or substantially flat, transfer surface in a first direction, while FIG.12 illustrates the flat, or substantially flat, surface in a seconddirection. Substantially flat, as used herein, means the transfersurface 136 used to support and transport a discrete article 102conforms to a plane within about 0-10 mm, and alternatively about 0-5mm, not including fluid ports and bolt holes, as discussed below.Example transfer surfaces 136 are illustrated as rectangular, but it isto be understood that other transfer surfaces for use with the transfermembers 112 of the present disclosure may be formed of other suitableshapes, such as squares, circles, or ovals, for example. A portion ofeach transfer surface 136 may be flat, or substantially flat, whileother portions may be arcuate. Although not illustrated, some of thetransfer surfaces of the transfer members of a transfer assembly may beflat, or substantially flat, while other transfer surfaces may bearcuate. The portions of the transfer members 112 supporting thetransfer surfaces 136 (e.g., the portions attached to the distal end ofthe housing 278 as described below) may be flat, substantially flat, orarcuate. In some instances, the transfer members 112 may be arcuate inone or more directions.

By providing flat, or substantially flat, transfer surfaces 136, asignificant advantage may be achieved in that the flatness of thetransfer surfaces 136 is the same, or substantially the same, whetherthe transfer surface 136 is in the first position 116 or rotated intothe second position 118 about the second rotation axis 164. In aninstance, a transfer surface 136 may have a flat, or substantially flatleading portion, an arcuate middle portion, and a flat, or substantiallyflat, trailing portion. This geometry of a transfer surface 136 may beemployed for substantially constant gap transfer at the leading andtrailing portions (and not the middle portion), for example. On relatedart transfer assemblies, having arcuate transfer surfaces with the arcextending generally in the longitudinal direction of the transfersurface, once the transfer member is rotated into the second position (aposition which is generally 90 degrees from the first position),transfer of the discrete articles may become an issue because of the arcbeing in the wrong direction for transfer to a second moving carriermember 106 or a head 105′ of the apparatus 101′. Stated another way, ifthe arc is suitable for picking up a discrete article from a firstmoving carrier member 104 or a head 105 of the apparatus 101, itgenerally may not be suitable for dropping off a discrete article onto asecond moving carrier member 106 or the head 105′ of the apparatus 101′because the outer edges of the transfer surface may be more distal fromthe second moving carrier member 106 or the head 105′ of the apparatus101′, potentially leading to inefficient transfers. The flat, orsubstantially flat, transfer surface 136 solves that problem byproviding the same, or substantially the same, distance or gap betweenall or most portions of the transfer surface 136 and the second movingcarrier member 106 or heads 105′ after the transfer surface 136 isrotated from the first position 116 into the second position 118 aboutthe second rotation axis 164. This can lead to improved discrete articletransfers and increased speed of the transfers.

One problem that may arise, however, in related art transfer assembliesusing flat, or substantially flat, transfer surfaces that do not havethe ability to move their transfer members radially inwardly andradially outwardly with respect to the rotation axis of the transferassemblies, may be that there will be a significant gap at the point ofdiscrete article transfer while portions of the flat, or substantiallyflat, transfer surface pass through the discrete article transfer pointor transfer zone. In such an instance, the leading edges and trailingedges of the flat transfer surface may be positioned quite close to themoving carrier member or head, while the middle portion of the transfersurface, owing to its flat, or substantially flat, configuration, may bepositioned more distal from the moving carrier member or heads. This gapbetween the middle portion of the flat, or substantially flat, transfermember and a moving carrier member or head and/or gap variation mayresult in poor or unacceptable transfers, especially during high speedtransfers, which are desired in absorbent article manufacturing. Thepoor transfer may result in folding of portions of the discrete articleover itself, for example.

Referring to FIGS. 7, 8, and 10C, the transfer assembly 100 solves thisgap problem, among others, in the middle portion of a related arttransfer surface by providing the track 134 with the projections 158 and160 therein at or proximate to the moving carrier members 104 and 106 orthe heads 105 and 105′. By providing the projections 158 and 160, thetransfer surfaces 136 of the transfer members 112 of the presentdisclosure may maintain a constant, or substantially constant (e.g.,0.1-2 mm or 0.1-3 mm), distance or minimum distance between themselvesand the moving carrier members 104 and 106 or the heads 105 and 105′ atthe point or zone of discrete article transfer. FIGS. 10A-10C illustratethe progression of the transfer surface 136 when moving past the head105′ in the direction of arrow A. FIGS. 13A-13C illustrate theprogression of the transfer surface 136 when moving past the head 105 inthe direction of arrow B. Similar constant, or substantially constant,distances or minimum distances, as illustrated in FIGS. 10A-10C and13A-13, would also apply to moving carrier members 104 and 106 if anapparatus 101 or 101′ was not provided on the input or output sides ofthe transfer assembly 100 and the discrete articles were transferreddirectly from a moving carrier member 104 or 106 to the transfer member112. In some forms, the distance may be constant, or substantiallyconstant, then not constant, and then constant, or substantiallyconstant again at the point or zone of discrete article transfers as thetransfer surface 136 moves past one of the moving carrier members or oneof the heads. The point or zone of discrete article transfer may be thepoint or zone at which a portion of the discrete article 102 leaves thefirst moving carrier member 104 or head 105 and transfers to thetransfer surface 136. The point or zone of discrete article transfer mayalso be the point or zone at which a portion of the discrete article 102leaves the transfer surface 136 and transfers to the second movingcarrier member 106 or head 105′. The point or zone of discrete articletransfer may also be where the moving carrier members, heads, and/ortransfer surfaces are closest to each other in their respectiverotations. Since the transfer surfaces 136 of the present disclosure areflat, or substantially flat, the transfer surfaces 136 generally mayneed to be moved radially outwardly and radially inwardly as portions ofthe transfer surfaces 136 pass through the discrete article transferpoint or zone with the moving carrier members 104 and 106 or the heads105 and 105′. The projections 158 and 160 constrain such radial movementof the transfer members 112 since the transfer members 112 are movablyengaged with the track 134 and rotate about a path about the rotationaxis 132 in correspondence with the track 134. As such, each of thetransfer members 112 and, thereby, the transfer surfaces 136 may bemoved or cammed consistently or variably radially outwardly relative tothe rotation axis 132 from when, or about when, the leading edge of thetransfer surface 136 is at or proximate to the point or zone of discretearticle transfer until when, or about when, a midpoint or mid portion(in the machine direction of travel) of the transfer surface 136 is ator proximate to the point or zone of discrete article transfer. At sucha time, the transfer surface 136 may then be moved or cammedconsistently or variably radially inwardly until the trailing edge ofthe transfer surface 136 is at or past the point or zone of discretearticle transfer or until the transfer member 112 has traveled over theprojection 158 or 160 and back onto a non-projection portion 162 of thetrack 134.

In various forms, the angular velocity of the rotation about the firstrotation axis 132 of the transfer members 112 may be or is constant, orsubstantially constant, in that the rotation of the drive shaft 148 andthe wheel 138 may be constant. That being said, the tangential velocityof the transfer surfaces 136 changes when the transfer members 112 aremoved radially outwardly and inwardly. Generally, if the transfermembers 112 are moved radially outwardly, the tangential velocity oftransfer surfaces 136 will increase, while if the transfer members 112are moved radially inwardly, the tangential velocity of the transfersurfaces 136 will decrease owing to the transfer members 112 beingrotated about the rotation axis 132. The tangential velocity of thetransfer surfaces 136 at the point or zone of discrete article transfermay be constant, or substantially constant (e.g., within 0.1%-2%) andmatched to the tangential velocity of the first or second moving carriermembers 104 or 106 or the heads 105 or 105′ during transfer. This isaccomplished by maintaining a substantially constant radial displacementbetween the zone of discrete article transfer and the first rotationaxis 132. The radial displacement of the transfer surface 136 isadjusted as the follower members 112 travel over the projections 158 and160. By providing constant, or substantially constant, tangentialvelocities of the transfer surfaces 136 at the point or zone of discretearticle transfer, smoother and matched speed discrete article transfersmay be accomplished. The projections 158 and 160 may be designed so thata first projection provides a transfer surface 136 with a firsttangential velocity at a first point or zone of discrete articletransfer (i.e., pick-up location) and a second projection provides thesame transfer surface 136 with a second tangential velocity at a secondpoint of discrete article transfer (i.e., drop-off location). As such,the transfer assembly 100 may pick up a discrete article 102 from thefirst moving carrier member 104 or the head 105 having a first velocityor tangential velocity at a first point or zone of discrete articletransfer and may drop off the discrete article 102 onto the secondmoving carrier member 106 or the head 105′ having a second velocity ortangential velocity at a second point or zone of discrete articletransfer. In an instance, the transfer assembly 100 may be configured topick up the discrete articles from the second moving carrier member 106or head 105′ and transfer them to the first moving carrier member 104 orhead 105. In such an instance, the direction of rotation of the transfermembers 112 about the rotation axis 132 may be clockwise orcounterclockwise.

Although the angular velocity and tangential velocity of the heads 105and 105′ may be variable, the angular velocity and tangential velocityof the heads 105 and 105′ may be constant, or substantially constant atthe point or zone of discrete article transfer. The angular velocity ortangential velocity of the heads 105 and 105′ may be the same as, orsubstantially the same as, the angular or tangential velocity of thetransfer members 112 at the point or zone of discrete article transfer.In other instances, the angular or tangential velocity of the heads 105and 105′ may be different than, greater than, or less than, the angularor tangential velocity of the transfer members 112 at the point or zoneof discrete article transfer, as will be discussed in greater detailbelow.

The transfer assembly 100 may be used to transfer discrete articles 102from the first moving carrier member 104 or the head 105 at a firstpitch (i.e., spacing of discrete articles) to a second moving carriermember 106 or the head 105′ at a second pitch (i.e., repitching). Thetransfer assembly 100 is capable of achieving suitable transfer of thediscrete articles 102 as the pitch increases, decreases, or remains thesame between the first and second moving carrier members 104 and 106 orbetween the heads 105 and 105′.

Transferring the discrete articles 102 from the head 105′ to the secondmoving carrier member 106 or from the transfer member 112 directly tothe second moving carrier member 106 may provide suitable and efficientbonding of the discrete articles 102 to the webs of front and rear belts124 and 126 or to front and rear belts. In an instance where thetransfer member 112 place the discrete articles 102 directly onto thesecond moving carrier member 106, the constant gap clearance, orsubstantially constant gap clearance, may be adjusted to provideuniform, or substantially uniform, bonding pressure between the transfersurface 136 and the second moving carrier member 106. The head 105′ andthe second moving carrier member 106 may also be adjusted to interferewith the discrete article 102 and create bonding pressure that will beconstant, or substantially constant, across the area of the discretearticle 102 or the area of a portion of the discrete article 102. Thismay be useful for creating suitable bonds between the discrete article102 and the webs of front and rear belts 124 and 126 when a hot meltadhesive or other pressure sensitive adhesive is employed.

The transfer assembly 100, with a variable radius transfer membermechanism, may also be employed to improve transfer from transfersurfaces that are not flat. For example, a transfer surface that isarcuate may benefit from adjusting the radial position of the transfersurface during transfer from the first moving carrier member 104 or thehead 105 or to the second moving carrier member 106 or the head 105′.Likewise, a transfer surface that has any non-flat surface can beadjusted radially to improve the transfer from the first moving carriermember 104 or the head 105 to the second moving carrier member 106 orthe head 105′. A person of ordinary skill in the art will recognize thatthe variable radius techniques described herein may be used with relatedart transfer assemblies as well as the transfer assemblies disclosedherein. As such, those concepts are encompassed by the presentdisclosure.

Referring to FIGS. 13-18, a rotation assembly 170 for one or more of, orall of, the transfer members 112 of the transfer assemblies 100discussed herein may be provided. Portions of the transfer assembly 100,some transfer members, and other components are eliminated in FIGS.13-18 for clarity in illustrating the rotation assembly 170. Therotation assembly 170 can be viewed on the transfer assembly 100 inFIGS. 7 and 8. The rotation assembly 170 may be simpler and less costlyto manufacture than a barrel cam-type rotation assembly, may haveextended follower member life, and may reduce the pressure angle of thetrack 134. As discussed above, the transfer assembly 100 may comprise aframe 130 defining a first rotation axis 132, wherein the one or moretransfer members 112 may rotate about the first rotation axis 132 (seee.g., FIGS. 3, 4, and 6-8). The rotation assembly 170 may rotateportions of the transfer member 112 about the second rotation axis 164between the first position 116 and at least a second position 118. Thefirst rotation axis 132 may be perpendicular, or substantiallyperpendicular (e.g., 0.5 to fifteen degrees), or transverse to thesecond rotation axis 164. In other instances, the first rotation axis132 may extend in a first direction and the second rotation 164 axis mayextend in a second, different direction. The first rotation axis 132 mayor may not intersect the second rotation axis 164.

Referring to FIGS. 13-20, the rotation assembly 170 may comprise atorque transmitting assembly 174 comprising an input member (or inputportion) 176 and an output member (or output portion) 178. The torquetransmitting assembly 174 may comprise a 90 degree gearbox or anothertype of gearbox. In other instances, the torque transmitting assemblymay not comprise a gearbox and instead may be another mechanism forachieving torque transmission between perpendicular, or substantiallyperpendicular, shafts, such as worm gearing, bevel gearing, hypoidgearing, helical gearing, belt drives, chain drives, hydraulic drives,and/or three-dimensional space mechanisms, for example. The input member176 and the output member 178 may be an input shaft and an output shaft,respectively. The shafts may have any suitable length and/or dimensions.The input member 176 may extend in a direction parallel to orsubstantially parallel to the first rotation axis 132 and the outputmember 178 may extend in a direction parallel to, substantially parallelto, or coaxial to the second rotation axis 164.

Referring to FIGS. 19 and 20, the torque transmitting assembly 174 maycomprise two or more gears. FIG. 19 is a partially cut away perspectiveview of the torque transmitting assembly 174, among other components,and FIG. 20 is a partially cut away top view of the torque transmittingassembly 174, among other components. The gears may each comprise teeth(not illustrated) meshingly engaged with each other. If two gears areprovided, a first gear 180 may be operably engaged with the second gear182 and may have a rotation axis 184 that is transverse, perpendicular,or substantially perpendicular to rotation axis 186 of the second gear182. The torque transmitting assembly 174 may be a speed increasingassembly, such as a 1 to 1.5, 1 to 2, 1 to 2.5, or 1 to 3 gearbox, forexample. Those of skill in the art will recognize that other speedincreasing assemblies may also be used and that the speed may beincreased any suitable amount. One example of a speed increasingassembly 174 is discussed in further detail below. In a form, the torquetransmitting assembly 174 may be a speed decreasing or equal speedassembly, such as a 2 to 1, or a 1 to 1, gearbox, for example. Those ofskill in the art will recognize that other speed decreasing assembliesmay also be used and that the speed may be decreased any suitableamount.

The rotation assembly 170 may also comprise a link or bar 188 comprisinga first end 190 operably coupled or fixedly attached to the input member176 and a second end 192 comprising a follower member 194. The inputmember 176 may be operably coupled to the link 188 using a key 172 orother mechanical component or assembly configured to cause the inputmember 176 to rotate when the link 188 is rotated about its first end190. Stated another way, the input member 176 may be non-rotatablyattached to the link 188, such that when the link 188 is rotated aboutits first end 190, the input member 176 rotates in unison with the firstend 190 of the link 188. The link 188 may be rotated about its first end190 when the follower member 194 is moved radially relative to the firstrotation axis 132 by a track 198, as discussed in greater detail herein.The follower member 194 may be a cam follower, which, in one form, maycomprise a roller rotatably attached to or engaged with the second end192 of the link 188. In various forms, the follower member may not be aroller and may be attached to or formed with the second end 192 of thelink 188. The one or more of the follower members 194 may comprisematerials such as metals, plastics, and/or polymers, for example, orcoatings thereof, to permit relative movement between the one or morefollower members 194 and the track 198 194 (also referred to as a secondtrack 198) for the follower members. The follower members 142 and thetrack 134 may comprise similar features. This second track 198 maysurround the first rotation axis 132 and be surrounded by the firsttrack 134 described above. In any event, the “inner” track 198 may beengaged with the follower member(s) 194 of the rotation assembly 170.The track 198 may comprise or be coated with the same, similarmaterials, or different materials as the follower members 170, forexample.

Referring again to FIGS. 13-18, the rotation assembly 170 may comprise ashaft or a shaft assembly 200 comprising a first end 202 engaged with oroperably coupled to the output member 178 of the torque transmittingassembly 174 and a second end 204 engaged with or operably coupled to aportion of the transfer member 112. The first end 202 of the shaft 200may be operably coupled to the output member 178 using the key 172 sothat when the output member 178 is rotated, the shaft 200 may be rotatedat least partially about the second rotation axis 164. Stated anotherway, the rotation of the output member 178 may drive the rotation of theshaft 200. A portion of, or all of, the shaft 200 may have a slot orgroove (not illustrated) defined therein in a direction extendingparallel to, or substantially parallel, to its longitudinal axis. A key(not illustrated) may extend from a portion of the transfer member 112or from the output member 178 at or proximate to the point of couplingto the shaft 200. The key may allow the transfer member 112 to be movedradially inwardly and outwardly relative to the first rotation axis 132as portions of the transfer member 112 rotate about the first rotationaxis 132 about a path in correspondence with the first track 134, asdiscussed above. The shaft 200 may extend into a portion of the transfermember 112, such as the fluid manifold 256 and the housing 278, or thetorque transmitting assembly 174 so that the distance between a shaftreceiving portion of the transfer member 112 and the output member 178(i.e., the length of the portion of the shaft 200 intermediate the shaftreceiving portion of the transfer member 112 and the torque transmittingassembly 174) may be varied. The key may also allow the shaft 200 to beturned about the second rotation axis 164 by the output member 178. Inessence, the key/slot feature allows the shaft 200 to be rotated aboutthe second rotation axis 164 and to vary the distance of the portion ofthe shaft 200 intermediate the shaft receiving portion of the transfermember 112 and the torque transmitting assembly 174.

The shaft may comprise a shaft assembly 200 comprising a spline 206 anda spline receiving member 208. The spline receiving member 208 may bepositioned on or engaged with a portion of the transfer member 112 orthe output member 178 at or proximate to the point of engagement with anend portion of the spline 206. If the spline receiving member 208 ispositioned on the output member 178, the output member 178 may be hollowsuch that the spline may extend therethrough. The spline 206 may beslidably engaged with the spline receiving member 208 such that thedistance between the most proximal portion of the transfer member 112and the output member 178 may be varied as the transfer member 112 ismoved radially relative to the first rotation axis 132. The end of thespline 206 not engaged with the spline receiving member 208 may beengaged with or operably coupled to the output member 178 or to aportion of the transfer member 112. In such a form, as the transfermember 112 is moved radially outwardly or radially inwardly as itcircumnavigates about the path of the first track 134, the length of theportion of the spline 206 intermediate the transfer member 112 and theoutput shaft 178 may be varied. The spline 206 and the spline receivingmember 208 may allow the output member 178 to rotate the spline 206about the second rotation axis 164 while the transfer member 112 ismoved radially relative to the first rotation axis 132. Those of skillin the art will recognize that other shaft assemblies that allowadjustment of the length of the portion of the shaft between thetransfer member 112 and the output member 178 are within the scope ofthe present disclosure.

Although not illustrated, a shaft assembly may comprise a shaft portionand a shaft receiving portion. The shaft may be slidably engaged withthe shaft receiving portion in a telescoping fashion (not illustrated)to allow axial expansion and contraction of the shaft assembly relativeto the first rotation axis. The shaft may be non-rotatably engaged withthe shaft receiving portion such that the output member 178 may rotatethe shaft and the shaft receiving portion.

Referring to FIGS. 7, 8, 10, and 13-15, the rotation assembly 170 may beengaged with the track or second track 198 positioned on or in the frame130 and surrounding the first rotation axis 132. The second track 198may be surrounded by the first track 134 such that the second track 198may be an inner track and the first track 134 may be an outer trackrelative to the first rotation axis 132. The inner track and the outertrack may be referred to as a track, a first track, or a second trackdepending on which of the tracks is recited first. Referring to FIG. 14,a first point 210 at a first location on the second track 198 may befirst distance, D1, away from the first rotation axis 132 and a secondpoint 212 at a second location on the second track 198 may be a seconddistance, D2, away from the first rotation axis 132. The first distance,D1, may be different than the second distance, D2. Other points on thesecond track 198 may be other distances away from the first rotationaxis 132. This distance variation of various points on the second track198 relative to the first rotation axis 132 may allow the shaft or shaftassembly 200 to rotate about the second rotation axis 164, therebymoving a portion of the transfer member 112 between the first position116 and at least the second position 118.

The second track 198 may be a cam track or a radial cam, for example. Inan instance, although not the illustrated form, but similar to the firstcam track 134, the second track 198 may extend outwardly from a frontplane of the frame 130 and form a projection that surrounds the firstrotation axis 132. In such a form, the second track 198 may be formedwith the frame 130 or may be attached to the frame 130. The projectionmay comprise a first side surface, a second side surface, and a topsurface. The first side surface may be positioned parallel to, orsubstantially parallel to (e.g., 0.5 to 15 degrees), the second sidesurface. The top surface of the projection may extend in a directionparallel to, or substantially parallel to, the plane of the frame 103and in a direction perpendicular to, or substantially perpendicular to,the first and second side surfaces. The distance between the first sidesurface and the second side surface may be constant, substantiallyconstant, or variable about the projection. Two follower members may beengaged with, attached to, or formed with the second end 192 of the link188 and may each be movably engaged with one of the side surfaces of theprojection. Two links, each comprising a follower member on their secondend, may be provided if two follower members are provided, as will berecognized by those of skill in the art. The follower members may bebiased toward the side surfaces of the projection.

Referring to FIGS. 13-15, the second track 198 may be a cam track orgroove defined in a front plane of the frame 130 and surrounding thefirst rotation axis 132. The cam track or groove may optionally besurrounded by a projection 214 positioned more radially outward from thefirst rotation axis 132 than the groove. The projection 214 may have aconstant width or may have a variable width throughout itscircumference. By providing the projection 214, the groove may bepartially, or fully, defined in a front plane of the frame 130. Thegroove may also be formed intermediate the projection 214 and anotherprojection 215 extending from the front plane of the frame 130. If theprojection 214 is not provided, the groove may be fully defined in afront plane of the frame 130. In various forms, one or more of thefollower members 194 may be at least partially positioned with the camtrack or groove 198 and may engage side walls of the second cam track orgroove 198 as the transfer member 112 rotates about the first rotationaxis 132. Any of the follower members 194, regardless of whether thesecond track 198 is a projection or a groove, may be moveably engagedwith the second track 198 and may circumnavigate about the firstrotation axis 132 about a path in correspondence with the second track198.

Referring to FIGS. 13-15, the groove of the second track 198 may have afirst surface 216 and a second surface 218 on a portion of the groovemost proximal to the rotation axis 132. The projection 214 may also havea first surface 220 and a second surface 222 on a portion of theprojection most proximal to the rotation axis 132. The first surface 216and the second surface 218 may extend different distances from the firstrotation axis 132. Likewise, the first and second surfaces 220 and 222may be positioned at different distances from the first rotation axis132. A distance between the first surface 216 and the first surface 220may be the same, or substantially the same, and, likewise, a distancebetween the second surface 218 and the second surface 222 may be thesame, or substantially the same. Stated another way, the first surface216 may be offset from the second surface 218 and the first surface 220may be offset from the second surface 222. In such a form, the secondend 198 of the link 188 may comprise a first follower member 194 and asecond follower member 194. The follower members 194 may be rotatablyengaged with the second end 198 of the link 188 using a pin, bolt, orother attachment mechanism or component. The follower members 194 may bepositioned adjacent to each other and may each rotate about the pin orbolt, for example. The first follower member 194 may be engaged with thefirst surface 216 and the second follower member 194 may be engaged withthe second surface 222. Surfaces 218 and 220 may not be engaged by thefollower members 194 due to the offset of the surfaces 218 and 220relative to the surfaces 216 and 222. By providing essentially two camtracks in the groove and two follower members 194, each follower membermay only turn in one direction. In other forms, the second track 198 mayonly have one surface on each side of the groove and only one followermember 194 may ride within the track 198.

Referring to FIGS. 7, 8, 10, and 13-20, when the one or more followermembers 194 are moved radially relative to the first rotation axis 132as they circumnavigate about the path in correspondence with the secondtrack 198, the link 188 may be rotated in a clockwise orcounterclockwise direction about its first end 190 thereby imparting arotational force or torque to the input member 176. The torquetransmitting assembly 174 may then impart the rotational force to theoutput member 178 and, thereby the shaft or the shaft assembly 200 owingto the gearing arrangement within the torque transmitting assembly 174.In a form, the input member 176 may be rotated with the first end 190 ofthe link 188 a first rotational distance and may impart a secondrotational distance to the output member 178 and, thereby the shaft orshaft assembly 200, owing to the gearing arrangement within the torquetransmitting assembly 174. The second rotational distance may be greaterthan the first rotational distance. The rotation of the shaft or theshaft of the shaft assembly 200 may cause the transfer member 112 tomove between the first position 116 and the second position 118 aboutthe second rotation axis 164. At least a portion of this rotationbetween the first position 116 and the second position 118 may occurwhen the first track 134 has radially expanded the distance between thetransfer member 112 and the output member 178 or when the transfermember 112 has been moved radially outwardly by the first track 134relative to the first rotation axis 132. The second rotation axis 164may be an axis formed about a longitudinal axis of the shaft or theshaft of the shaft assembly 200. In one revolution of the transfermember 112 about the first rotation axis 132, the shaft or the shaft ofthe shaft assembly 200 may be rotated from the first position 116 intothe second position 118 and back into the first position 116. Thetransfer surfaces 136 may be rotated between about 45 degrees to about180 degrees, about 60 degrees to about 150 degrees, about 75 degrees toabout 105 degrees, about 90 degrees (e.g., plus or minus 3 degrees), or90 degrees, specifically reciting all 0.5 degree increments within theabove-specified ranges and all ranges formed therein or thereby, whenthe transfer member 112 is moved between the first position 116 and thesecond position 118.

The second track 198 may vary the angle of the transfer member 112rotating about the second rotation axis 164 due to the changing radiusof the follower member 194. The second track 198 may also have dwellregions therein where the radius of the follower members 194 and therotation angle of the transfer members 112 remain constant, orsubstantially constant. These dwell regions may be useful when thetransfer member is in the first position 116 and in the second position118 during the transfer of the discrete articles 102 from the firstmoving carrier member 104 or the head 105 to the second moving carriermember 106 or the head 105′.

Although the rotation assembly 170 is illustrated in use with thetransfer assembly 100 as an example, the rotation assembly 170 may beapplied to other transfer assemblies known to or developed by those ofskill in the art and may function independently of the transfer assembly100. Other transfer assemblies than the rotation assembly 170 of thepresent disclosure may be used with may not have transfer members thatmove radially relative to the first rotation axis 132. In one example,the rotation assembly 170 may be used with transfer members that have avarying angular position about the first rotation axis 132, for example.

The transfer members 112 may be cammed or moved radially outwardly toprovide clearance for rotation of the transfer members 112 about thesecond rotation axis 164 with adjacent transfer members 112. In otherinstances, the spacing or shape of the transfer members 112 may notrequire increasing their radial position for rotation about the secondrotation axis 164. In another form, the radius of the transfer members112 may decrease to provide clearance for transfer member rotation aboutthe second rotation axis 164. In another instance, the transfer members112, or portions thereof, may tilt relative to first rotation axis 132to allow clearance with adjacent transfer members 112 during rotationabout the second rotation axis 164.

A method of transferring one or more discrete articles from a firstmoving carrier member or head of an apparatus to a second moving carriermember or head of an apparatus using a transfer assembly is provided.The transfer assembly may comprise a frame defining a first rotationaxis and one or more transfer members each comprising a transfer surfaceconfigured to receive one or more of the discrete articles. The methodmay comprise rotating the one or more transfer members about the firstrotation axis and selectively varying the radial distance of the one ormore transfer surfaces relative to the first rotation axis as the one ormore transfer member rotate about the first rotation axis. The methodmay also comprise rotating the one or more transfer surfaces, and otherportions of the transfer members, about a second rotation axis between afirst position and at least a second position using a track thatsurrounds the first rotation axis, one or more follower memberscircumnavigating about a path in correspondence with the track while thetransfer member rotates about the first rotation axis, a torquetransmitting assembly, a link comprising a first end operably coupled toa first portion of the torque transmitting assembly and a second endcomprising the one or more follower members, and a shaft assemblyoperably engaged with a second portion of the torque transmittingassembly on a first end and engaged with a portion of the transfermember on a second end. The first portion or input portion of the torquetransmitting assembly may be positioned parallel to, or substantiallyparallel to, the first rotation axis and the second portion or outputshaft of the torque transmitting assembly may be positioned parallel to,or substantially parallel to, the second rotation axis. The method maycomprise expanding and contracting the length of the shaft assemblybetween each transfer member and each output portion during theselectively varying of the radial distance of the one or more transfersurfaces relative to the first rotation axis. The method may alsocomprise rotating the one or more transfer surfaces at least partiallybetween the first and second positions when the length of the shaftassemblies between the transfer members and the output portions areexpanded and turning the discrete article through the rotation of thetransfer surfaces between the first position and the second position.The transfer surfaces, and other portions of the transfer members, maybe rotated from the first position into the second position in a firstdirection of rotation and may be rotated from the second position intothe first position in a second direction of rotation. The firstdirection of rotation may be opposite to the second direction ofrotation. In other instances, the first direction of rotation may be thesame as the second direction of rotation. One or more of the discretearticles may be retained to or pushed from the transfer surfaces using afluid pressure, such as a negative or a positive fluid pressure, forexample.

The various discrete articles 102 (e.g., a chassis of an absorbentarticle) or flexible discrete articles 102 may be retained to thevarious transfer surfaces 136 of the transfer members 112 or thesurfaces of the heads 105 and 105′ of the present disclosure in manyways, including but not limited to, fluid pressure, mechanicalattachment via pins or grippers, adhesives, such as pressure sensitiveor low tack adhesives, static attraction, and/or magnetic attraction,for example. Fluid pressures and/or other forces may also be used toforce or move the discrete articles 102 from the transfer surfaces 136or surfaces of the heads 105 and 105′ onto a moving carrier member, suchas the second moving carrier member 106.

Referring to FIGS. 1, 4-6, 8, 9, 16, and 18, for example, the transferassembly 100 may comprise a fluid system configured to retain thediscrete articles 102 to one or more of the transfer surfaces 136 of thetransfer members 112. Each of or one of the transfer members 112 mayhave one or more fluid ports 230 defined through the transfer surface136 thereof, or through portions or zones of the transfer surface 136.The fluid ports 230 may have any suitable shape, such as elongate slots,circular or ovate openings, and/or rectangular, square, or triangularopenings, for example. The fluid ports 230 may also have mesh, screen,or other porous materials extending thereover. The fluid ports 230 maybe linear or non-linear, continuous or non-continuous. In a form, afirst transfer member may have a transfer surface having a first patternof fluid ports and a second transfer member may have a transfer surfacehaving a second pattern of fluid ports. In other instances, the patternson all of the transfer surfaces 136 may be the same. A positive or anegative (vacuum) fluid pressure may be applied to the fluid ports 230through various fluid conduits and fluid lines. Some fluid ports, atvarious times, may not have any fluid pressure being applied thereto.The fluid pressures may initiate in one or more fluid movement devicesor sources 232, 234, such as one or more fluid pumps, vacuum pumps,pressure blowers, or fans. The fluid may be air or other gas, forexample. Some fluid ports 230 may be configured to provide a positivepressure, while at the same time, other fluid ports 230 of the sametransfer member 112 may be configured to provide a negative pressure orno fluid pressure. In various instances, some of the fluid ports 230 maybe configured to provide a first fluid pressure (positive or negative),while at the same time, other fluid ports 230 of the same transfermember 112 may be configured to provide a second fluid pressure(positive or negative). The first fluid pressure may be greater than orless than the second fluid pressure. In other instances, the fluid ports230 in one transfer member 112 may have a different fluid pressure asthe fluid ports 230 in another transfer member 112 on the same transferassembly 100 owing to factors like the number of the fluid ports 230 orthe areas of the fluid ports 230 on a particular transfer surface 136.For example, one fluid pressure may be applied at a pick-up location andanother fluid pressure may be applied at a drop-off location. In otherinstances, the fluid pressure applied to the fluid ports 230 may vary indifferent fluid ports 230 or zones of the fluid ports 230 in a transfermember 112 at the pick-up location and at the drop-off location.

Referring to FIGS. 1 and 4-9, the fluid system used to provide the fluidpressure to the fluid ports 230 may comprise the first fluid movementdevice 232 and the second fluid movement device 234. The first andsecond fluid movement devices 232 and 234 may supply a positive fluidpressure and/or a negative fluid pressure to first and second fluidlines 236 and 238. The first and second fluid movement devices 232 and234 may be controlled independently or controlled together for variousapplications. In an instance, only one fluid movement device may beprovided. That single fluid movement device may be configured to supplythe first and second fluid lines 236 and 238 with positive and/ornegative fluid pressures. The fluid pressure and flow rates applied tothe first and second fluid lines 236 and 238 may be equal or different.In an instance, the single fluid movement device may supply a positivepressure to the first fluid line 236 and a negative pressure to thesecond fluid line 238, for example.

Referring now to FIGS. 1 and 4-6, the apparatuses 101 and 101′ will bediscussed in greater detail. As stated herein, in certain instances,only one apparatus may be provided on either the input side or outputside of the transfer assembly 100. If the apparatus 101 is provided onlyon the input side of the transfer assembly 100, the discrete articles102 may be transferred from the first moving carrier 104 to a head 105of the apparatus 100, then from the head 105 of the apparatus 101 to thetransfer member 112, and then from the transfer member 112 directly tothe second moving carrier member 106. If the apparatus 101′ is providedonly on the output side of the transfer assembly 100, the discretearticles 102 may be transferred directly from the first moving carriermember 104 to the transfer member 112, then from the transfer member 112to the head 105′ of the apparatus 101′, and then from the head 105′ tothe second moving carrier member 106. In certain operations, more thanone apparatus may also be provided on either the input side or theoutput side of the transfer assembly, or both. In other certaininstances, the first and/or second moving carrier members 104 and 106may be eliminated and only the apparatus 101 and/or 101′ may be used.

Each of the apparatuses 101 and 101′ may comprise one or more heads 105and 105′, respectively. Each apparatus 101 and 101′ may have a rotationaxis 107 and 107′, respectively. The heads 105 and 105′ may be rotatedabout the rotation axis 107 and 107′, respectively, at a variableangular velocity or at a plurality of angular velocities. For example,each of the heads 105 and 105′ may be rotated about a first, second,third, fourth or more angular velocities within one revolution of thehead about the rotation axis 107 and 107′, respectively.

Referring to FIGS. 21 and 22, an example apparatus comprising a singlehead is illustrated. The apparatus 101 may comprise a motor 161 fortransmitting rotational energy to a transfer device 171. The motor 161may be operably linked or operably engaged with the transfer device 171using any technique known to those skilled in the art such as, forexample, a gear to gear connection, transmission belting and pulleys,gearboxes, direct couplings, and the like or any combinations thereof.For example, in FIG. 21 the transfer device 171 may comprise a drivengear 173 that is connected to a driving gear 163, which transmitsrotational energy to the driven gear 173. In use, the driving gear 163may engage and rotate the driven gear 173 which, in turn, may rotate ahead 105 of the apparatus 101 about rotation axis 107. The apparatus101′ and the head 105′ may be generally the same as, or very similar to,that described for the apparatus 101 and the head 105. In otherinstances, the apparatus 101′ and/or the head 105′ may be different insize, speed, and/or configuration, for example.

In some instances, the transfer device 171 may be formed with a portionof the head 105. The head 105 may comprise a surface 153 configured toreceive a discrete article 102. The head 105 may be connected to thetransfer device 171 by any technique known to those skilled in the artsuch as, for example, bolts, screws, pins, keys and matching key ways,connector parts such as shafting or brackets, adhesive bonding orgluing, welding and the like or combinations thereof. For instance, thehead 105 shown in FIG. 21 may be connected directly to the driven gear173 by fitting the end of the head 105 into a mating hole in the drivengear 173 and locking it into position with a pin. In other instances,the head 105 may be formed with the transfer device 171.

The dimensions of the head 105 may vary depending upon the desiredoutput of the apparatus 101 and the size and shape of the discretearticles 102 being transferred. The head 105 may comprise acrescent-shaped member having an outer, peripheral arc length spanningfrom about 5 degrees to about 355 degrees, an outer radius ranging fromabout 10 mm to about 1,000 mm or about 25 mm to about 500 mm, and awidth ranging from about 25 mm to about 1,000 mm or about 50 mm to about750 mm, specifically reciting all 0.1 increments within theabove-specified ranges and all ranges formed therein or thereby. Othersuitable dimensions are also within the scope of the present disclosure.As the transfer device 171 rotates, the head 105 may travel in thedirection indicated by arrow 93 as shown in FIG. 22. The head 105 maypass through a pick-up zone and a drop-off zone as it rotates about therotation axis 107. In the pick-up zone, the head 105 may receive adiscrete article 102 from the first moving carrier member 104 (ifpresent) (on the input side of the transfer apparatus 100) and the head105′ may receive the discrete article 102 from the transfer member 112(on the output side of the transfer apparatus 100). In the drop-offzone, the head 105 may provide a discrete article 102 to a transfermember 112 (on the input side of the transfer apparatus 100) and thehead 105′ may provide the discrete article 102 to the second movingcarrier member (if present) (on the output side of the transferapparatus 100).

The motor 161 may be configured to move the head 105 at a plurality ofangular velocities throughout one full revolution of the head about therotation axis 107.

One illustrated example of the motor 161 comprises, or is operablylinked to, a rotatable circular driving gear 163 operably connected toan input shaft 165. In this example, the input shaft 165 is the outputshaft of the motor 161. The transfer device 171 may be placed parallelto the motor 161 such that the driving gear 163 meshes with the drivengear 173 using gear set-ups known to those skilled in the art. In use,the motor 161 may rotate the input shaft 165, which rotates the drivinggear 163, which, in turn, rotates the driven gear 173 and, thereby,rotates the head 105 about the rotation axis 107. A similar method ofoperation would apply to the apparatus 101′ and the head 105′.

In other forms, the transfer device 171 may comprise any mechanism ormechanisms known to those skilled in the art by which rotational energymay be conducted from one shaft to another such as, for example,v-belts, timing belts, continuous chains and the like or combinationsthereof. Further, the transfer device 171 may comprise any mechanism ormechanisms known to those skilled in the art by which input velocity canbe variably modified to an output source such as, for example, cams,linkages, and the like or combinations thereof as long as the changes inrotational speed are substantially created by the motor 161. It will befurther appreciated that the apparatuses 101 and 101′ of the presentdisclosure may utilize one or, in the alternative, two, three, four ormore combinations of heads 105 or 105′.

The heads 105 and 105′ may comprise one or more gripping mechanism sothat the surface of the heads 105 and 105′ may engage a discrete article102. The gripping mechanism(s) may comprise a fluid pressure (e.g.,vacuum) that may be selectively imposed through fluid ports the head 105leading to the surface 153 of the head 105. For instance, the fluidpressure may be activated when picking up a discrete article 102 anddeactivated when releasing the discrete article 102. In other instances,a negative fluid pressure (i.e., vacuum) may be activated when pickingup the discrete article 102 in a pick-up zone and a positive fluidpressure may be activated to “blow off” the discrete article 102 in adrop-off zone. In this manner, control may be maintained over thediscrete articles 102 at all times during the transfer process.Alternatively, the gripping mechanism(s) may comprise any techniqueknown to those skilled in the art for gripping and releasing discretearticles 102 such as, mechanical clamps, adhesives, electrostaticcharges, electrical clamps, magnetic clamps, and the like orcombinations thereof.

The motor 161 may comprise a programmable motor, such as a programmablerotary motor or a programmable linear motor. The use of a programmablemotor may provide an inexpensive and adaptable method for receiving thediscrete articles 102 at a first tangential and angular velocity andapplying the articles at a second, different tangential and angularvelocity. The variable angular velocity of the head 105 throughout onerevolution of the head 105 about the rotation axis 107 may be producedby varying the current supplied to the motor 161. Since the transferdevice 171 is operably coupled to the output of the motor 161, changesin the angular velocity and position of the motor 161 may directlycorrelate to changes in the angular velocity and position of the head105. The current supplied to the motor 161 may be controlled using anyof a variety of methods for programming motors known to those skilled inthe art such as, standard cam curve functions, a reference data tablecontaining reference points, desired motor encoder points, and the likeor combinations thereof.

The programmable motors used to drive the heads 105 and 105′ may providevariable angular velocities to the heads 105 and 105′, including periodswhere the angular velocity remains constant for a fixed duration. Theseconstant angular velocity dwell times may be advantageous when pickingup and transferring a discrete article, particularly when the pick-upand transfer occurs over substantial arc lengths of contact.Alternatively, one or more of the constant speed regions may be changedto a controlled variable speed region. This may enable the discretearticle 102 to be picked up at a variable speed, which, when thediscrete article 102 is elastic, would allow tensions to be variedincrementally therein which may be desirous in certain product features.In another example, the constant speed of the motor 161 in a drop-offzone may be such that the corresponding speed of the head 105 isdifferent from, such as less than, the speed of the second movingcarrier member 106 at transfer. Such speed variations may generatetension in the discrete article 102 by incrementally transferring thediscrete article 102 in a controlled manner from the head 105′ travelingat a first tangential speed to the second moving carrier member 106moving at a second tangential speed or linear speed when the secondmoving carrier member is a linear conveyor.

It will be further appreciated that the tangential and angularvelocities of the head 105 outside of the pick-up and drop-off zones maybe tailored to aid the performance of secondary processes includingadhesive application, printing of identification or registration marks,application of bonding aids, moisture addition, and the like andcombinations thereof. Such changes in the tangential and angularvelocities may be beneficial by presenting specific velocity profiles oreven additional periods of constant velocity, which may allow for moreprecise interaction with the secondary processes being performed.

Programmable motors may be purchased from any number of suppliers ofprogrammable motors such as Rockwell Automation, located in Milwaukee,Wis. Further, the program inputs to the motors can be generated by oneof ordinary skill in the art if provided with the analyticalrepresentation of the desired output function. For instance, thecreation of the electronic cam profile for the motor may be developed byfirst determining the key input variables. Some key input variables arebased on desired product features, the base design of the apparatus 101and the desired cycle speed of the apparatus 101. Secondly, the radiusof the outer surface of the head 105 is determined Once the radius isdetermined, the required cam inputs of rotational velocities, distancestraveled and time available for acceleration may be calculated, whichserve as the input to the cam profile generator. Additional detailsregarding these calculations are disclosed, for example, in U.S. Pat.No. 6,450,321 to Blumenthal et al.

Referring to FIGS. 23 and 24, another example form of an apparatus 101of the present disclosure is illustrated. The apparatus 101 may compriseone or more heads 105 engaged with or formed with a base 173, and amotor or programmable motor 161. The base 173 may be directly engagedwith a drive shaft 158 of the motor or programmable motor 161. This isknown as direct drive. The base 173 and the drive shaft 158 may togetherbe known as the transfer device 171. The base 173 is directly driven bythe drive shaft 158 of the programmable motor 161. Stated another way,when the drive shaft 158 is rotated, the base 173 is rotated about anaxis of rotation 107. The heads 105, owing their engagement with thebase 173, are then are orbited about the axis of rotation 107. In someinstances, another apparatus, similar to the apparatus 101 may beprovided opposite to apparatus 101, such that they can work on unison.In such an instance, the rotation axes of each apparatus may bepositioned coaxially with the heads extending between the motors of theapparatuses.

FIG. 25 illustrates a portion of the apparatus 101 comprising a base 173and two heads 105 extending from the base. The rotation axis of theheads 105 is indicated as 107. The heads 105 may each have fluid ports109 defined therein, such that one or more fluid pressures may beprovided at the surface 153 of the heads 105.

Referring to FIGS. 26 and 27, the heads 105 may each define one or morefluid cavities 111 therein. The surface 153 may define one or more fluidports 109 therein. The one or more fluid ports 109 may be in at leastpartial fluid communication with the one or more fluid cavities 111 sothat fluid pressure (positive and/or negative) may be applied todiscrete articles 102 positioned on the surface 153 of the heads 105 inlocations where the discrete articles 102 overlap the one or more fluidports 109. The one or more fluid cavities 111 may be in fluidcommunication with one or more fluid pumps (see e.g., fluid pump 115 inFIG. 21) configured to provide a positive and/or negative fluid pressureto the fluid cavities 111. In a form, one fluid pump may be configuredto provide a positive fluid pressure and another fluid pump may beconfigured to provide a negative fluid pressure. One or more of thefluid pumps may be in fluid communication with a manifold on theapparatus which is in fluid communication with at least some of thefluid cavities 111. In such an instance, positive and/or negative fluidpressure may be provided by the manifold to the at least some fluidcavities 111 as desired and as will be recognized by those of skill inthe art.

Referring to FIG. 27, an example cross-sectional view of the head 105taken about line 27-27 of FIG. 7 is illustrated. A fluid cavity 111 isformed within the head 105 and is in fluid communication with the fluidports 109 (see FIG. 25). An optional support material 113 may bepositioned within the head 105 and at least partially surround the fluidcavity 111. The support material 113 may comprise a low densitymaterial, a low density foam, a plastic material, a non-foam material,or a foam material, for example. The support material may have channelsin it so that the fluid cavity 111 may be in fluid communication withthe fluid ports 109. The support material, in some instances, may alsomerely be portions of the head and made of the same materials as thehead.

Each programmable motor may be in electrical communication with a motorcontrol system. The motor control system may comprise an amplifierand/or a controller. Example motor control systems 270 are illustratedin FIGS. 21-24. The motor control system 270 may regulate, control,and/or vary the speed at which the programmable motor runs throughout anorbit, or partial orbit, of the head 105 causing the head 105 toincrease or decrease in speed based on where it is in its rotation.

A portion of the apparatus 101 (or 101′) comprising the head 105 (or105) is illustrated in FIGS. 28A-28C. The head 105 of the apparatus 101is shown in different positions of rotation about the rotation axis 107and engaged with a discrete article 102. During one revolution of thehead 105 about the rotation axis 107, the head 105 may have a firstangular velocity, AV1 (FIG. 28A), a second angular velocity, AV2 (FIG.28B), and a third angular velocity, AV3 (FIG. 28C). The first, second,and third angular velocities may all be different. Alternatively, atleast one of the first, second, and third angular velocities may bedifferent than the other two. In other instances, the head 105 may havemore than three different angular velocities within one revolution aboutthe rotation axis 107. By rotating the head 105 at a plurality ofangular velocities within one revolution about the rotation axis 107,the head 105 may be able to pick up the discrete article 102 whilemoving at the first angular velocity, AV1, accelerate or decelerate tothe second angular velocity, AV2, and then drop off the discrete article102 at the third angular velocity, AV3. The first and third angularvelocities may be same or different. In an instance, the first and thirdangular velocities may be constant, or substantially constant,throughout a pick-up zone or a drop-off zone, while the second angularvelocity, AV2, may be variable. The second angular velocity, AV2, may beused when the head 105 is outside of a pick-up zone or a drop-off zonefor the discrete article 102.

Again referring to FIGS. 28A-28C, a surface of the head 105 (or 105) mayhave a plurality of tangential velocities within one revolution of thehead 105 about the rotation axis 107. The tangential velocities may beTV1 (FIG. 28A), TV2 (FIG. 28B), and TV3 (FIG. 28C). All of thetangential velocities may be the same or different. In an instance, atleast one of the tangential velocities may be different than the othertwo tangential velocities. By rotating the surface of the head 105 at aplurality of tangential velocities within one revolution about therotation axis 107, the surface of the head 105 may be able to pick upthe discrete article 102 while moving at the first tangential velocity,TV1, accelerate or decelerate to the second tangential velocity, TV2,and then drop off the discrete article 102 at the third angularvelocity, TV3. The first and third tangential velocities may be same ordifferent. In an instance, the first and third tangential velocities maybe constant or substantially constant throughout a pick-up zone or adrop-off zone, while the second tangential velocity may be variable. Thesecond tangential velocity, TV2, may be used when the head 105 isoutside of a pick-up zone or a drop-off zone for the discrete article102.

FIGS. 29A-29C schematically illustrate the transfer of a discretearticle 102 progressing through a drop-off zone between a transfermember 112 of the transfer assembly 100 and a head 105′ of the apparatus101′, as an example, although a similar concept would apply at adiscrete article pick-up zone when the head 101 is transferring thediscrete article 102 to the transfer member 112. The transfer member 112is rotating about the rotation axis 132 of the transfer assembly 100 andthe head 105′ is rotating about the rotation axis 107′. In FIGS.29A-29C, the transfer member 112 may have a constant, or substantiallyconstant, angular velocity, AV1, at the point or zone of discretearticle transfer. The head 105′ may have an angular velocity, AV2, thatmay be constant, or substantially constant, at the point or zone ofdiscrete article transfer. The angular velocity, AV1, may be equal to,or substantially equal to, the angular velocity, AV2 at the point orzone of discrete article transfer. In other instances, the angularvelocity, AV1, may be less than, greater than, or different than theangular velocity, AV2, at the point or zone of discrete articletransfer. FIG. 29A illustrates the beginning of an example discretearticle transfer. FIG. 29B illustrates a middle portion of the examplediscrete article transfer. FIG. 29C illustrates the end of the examplediscrete article transfer. It is to be noted that the constant, orsubstantially constant, minimum gap or distance may be providedintermediate the surface 136 of the transfer member 112 and a surface ofthe head 105′ to ensure smooth and reliable transfer without fold-overof portions of the discrete article 102. The constant, or substantiallyconstant, minimum gap or distance is described in further detail above.

FIGS. 30A-30C schematically illustrate the transfer of a discretearticle 102 progressing through a drop-off zone between the transfermember 112 of the transfer assembly 100 and a head 105′ of the apparatus101′, as an example, although a similar concept would apply at adiscrete article pick-up zone when the head 105 transfers the discretearticle 102 to the transfer member 112. The transfer member 112 isrotating about the rotation axis 132 of the transfer assembly 100 andthe head 105′ is rotating about the rotation axis 107′. In FIGS.30A-30C, the transfer surface 136 of the transfer member 112 may have aconstant, or substantially constant, tangential velocity, TV1, at thepoint or zone of discrete article transfer. The head 105′ may have atangential velocity, TV2, that may be constant, or substantiallyconstant, at the point or zone of discrete article transfer. Thetangential velocity, TV1, may be equal to, or substantially equal to,the tangential velocity, TV2, at the point or zone of discrete articletransfer. In other instances, the tangential velocity, TV1, may be lessthan, greater than, or different than the tangential velocity, TV2, atthe point or zone of discrete article transfer. FIG. 30A illustrates thebeginning of an example discrete article transfer. FIG. 30B illustratesa middle portion of the example discrete article transfer. FIG. 30Cillustrates the end of the example discrete article transfer. It is tobe noted that the constant, or substantially constant, minimum gap ordistance may be provided intermediate the surface 136 of the transfermember 112 and a surface of the head 105′ to ensure smooth and reliabletransfer without fold-over of portions of the discrete article 102. Theconstant, or substantially constant, minimum gap or distance isdescribed in greater detail above.

FIGS. 31A-31C schematically illustrate the transfer of a discretearticle 102 progressing through a drop-off zone between the transfermember 112 of the transfer assembly 100 and a head 105′ of the apparatus101′, as an example, although a similar concept would apply at adiscrete article pick-up zone when the head 105 transfers the discretearticle 102 to the transfer member 112. The transfer member 112 isrotating about the rotation axis 132 of the transfer assembly 100 andthe head 105′ is rotating about the rotation axis 107′. In FIGS.31A-31C, the transfer surface 136 of the transfer member 112 may have aconstant, or substantially constant, tangential velocity, TV1, at thepoint or zone of discrete article transfer. The surface of the head 105′may have a tangential velocity, TV2, that may be constant, orsubstantially constant, at the point or zone of discrete articletransfer. Alternatively, the tangential velocity, TV2, of the surface ofthe head 105′ may be variable at the point or zone of discrete articletransfer. The tangential velocity, TV1, may be less than, the tangentialvelocity, TV2, at the point or zone of discrete article transfer totension the discrete article being transferred. The tangential velocity,TV2, of the surface of the head 105′ may be at least about 2% to about35%, at least about 2% to about 30%, at least about 5% to about 25%, atleast about 3% to about 25%, at least about 3%, at least about 5%, atleast about 10%, or at least about 15%, specifically reciting all 0.1%increments within the specified ranges and all ranges formed therein orthereby, greater than the tangential velocity, TV1, of the transfersurface 136 at the point or zone of discrete article transfer to tensionthe discrete article 102 being transferred. Tensioning of the discretearticles being transferred may allow for multiple product sizes to berun using the same transfer assembly 100. The tensioning essentially maycreate a situation of controlled slippage of the discrete articles fromone component to another component where a shorter discrete article canbe transferred to a larger head. Further, the tensioning may at leastpartially remove wrinkles in the discrete articles being transferred.Also, the tensioning may at least partially improve control of thediscrete articles during transfer, as the tensioning may at leastpartially limit the discrete articles from being disturbed by moving airor other factors that negatively impact the transfer.

FIG. 31A illustrates the beginning of an example discrete articletransfer, including tensioning of the discrete article 102. FIG. 31Billustrates a middle portion of the example discrete article transfer,including tensioning of the discrete article 102. FIG. 31C illustratesthe end of the example discrete article transfer, including tensioningof the discrete article 102. It is to be noted that the constant, orsubstantially constant, minimum gap or distance may be providedintermediate the surface 136 of the transfer member 112 and a surface ofthe head 105′ to ensure smooth and reliable transfer without fold-overof portions of the discrete article 102. The constant, or substantiallyconstant, minimum gap or distance is described in greater detail above.

FIGS. 32A-32C schematically illustrate transfer of a discrete article102 from the head 105′ of the apparatus 101′ to the second movingcarrier member 106 (or to webs moving over the second moving carriermember). The head 105′ rotates about the rotation axis 107′ of theapparatus 101′, while the second moving carrier member 106 rotates aboutrotation axis 117. A surface of the head 105′ has a first tangentialvelocity, TV1, at the point or zone of discrete article transfer. Thefirst tangential velocity, TV1, may be constant, or substantiallyconstant at the point or zone of discrete article transfer. A surface ofthe moving carrier member 106 may have a second tangential velocity,TV2, at the point or zone of discrete article transfer. The secondtangential velocity, TV2, may be equal to, substantially equal to,greater than, or less than, the first tangential velocity, TV1, at thepoint or zone of discrete article transfer. If the second tangentialvelocity, TV2, is greater than the first tangential velocity, TV1, atthe point or zone of discrete article transfer, the discrete article 102may be tensioned during the transfer. The second tangential velocity,TV2, may be at least about 2% to about 35%, at least about 2% to about30%, at least about 5% to about 25%, at least about 3% to about 25%, atleast about 3%, at least about 5%, at least about 10%, or at least about15%, specifically reciting all 0.1% increments within the specifiedranges and all ranges formed therein or thereby, greater than the firsttangential velocity, TV1, at the point or zone of discrete articletransfer to tension the discrete article 102 being transferred. On theinput side of the transfer assembly 100, a surface of the first movingcarrier member 104 may have a tangential velocity that is slower thanthe tangential velocity of a surface of the head 105 to tension thediscrete article at the point or zone of discrete article transfer.

FIGS. 33A-33C schematically illustrate transfer of a discrete article102 from the head 105′ of the apparatus 101′ to a linear conveyor 106′.The head 105′ rotates about the rotation axis 107′ of the apparatus101′. A surface of the head 105′ has a first tangential velocity, TV1 atthe point or zone of discrete article transfer. The first tangentialvelocity, TV1, may be constant, or substantially constant at the pointor zone of discrete article transfer. A surface of the linear conveyor106′ may have a linear velocity, LV2. The linear velocity, LV2, may beequal to, substantially equal to, greater than, or less than the firsttangential velocity, TV1, at the point or zone of discrete articletransfer. The linear velocity, LV2, may be at least about 2% to about35%, at least about 2% to about 30%, at least about 5% to about 25%, atleast about 3% to about 25%, at least about 3%, at least about 5%, atleast about 10%, or at least about 15%, specifically reciting all 0.1%increments within the specified ranges and all ranges formed therein orthereby, greater than the first tangential velocity, TV1, at the pointor zone of discrete article transfer to tension the discrete article 102being transferred. On the input side of the transfer assembly 100, asurface of a linear conveyor may have a tangential velocity that isslower than the tangential velocity of a surface of the head 105 totension the discrete article at the point or zone of discrete articletransfer.

In a form, a method of transferring discrete articles between a transferassembly comprising one or more transfer members and an apparatuscomprising one or more heads is provided. The discrete articles may betransferred from a transfer surface of the transfer member to a surfaceof the head of the apparatus (output side of transfer assembly) and/ormay be transferred from the surface of the head of the apparatus to thetransfer surface of the transfer member (input side of transferassembly). The transfer assembly may comprise a frame defining a firstrotation axis and at least one transfer member each comprising atransfer surface configured to receive one or more of the discretearticles. The method may comprise rotating the transfer member of thetransfer assembly about the first rotation axis at a substantiallyconstant angular velocity, maintaining the transfer surface at asubstantially constant minimum distance away from a surface of the headat a point or zone of discrete article transfer, and rotating the headof the apparatus about a second rotation axis at a plurality of angularvelocities. A first angular velocity of the head may be constant, orsubstantially constant, at the point or zone of discrete articletransfer. Alternatively, the first angular velocity of the head may bevariable at the point or zone of discrete article transfer.

A tangential velocity of the transfer surface of the transfer member maybe constant, or substantially constant, at the point or zone of discretearticle transfer. A tangential velocity of the surface of the head ofthe apparatus may be the same as, or substantially the same as (e.g.,+/−2%), the constant, or substantially constant, tangential velocity ofthe transfer surface at the point or zone of discrete article transfer.In some instances, the tangential velocity of the surface of the head ofthe apparatus may also be variable at the point or zone of discretearticle transfer and/or may be different than the constant, orsubstantially constant, tangential velocity of the transfer surface atthe point or zone of discrete article transfer.

The method may comprise rotating the head of the apparatus about thesecond rotation axis (e.g., rotation axis 107) at a second angularvelocity when the head is outside of a zone of discrete articletransfer. The second rotation axis may be parallel to, substantiallyparallel to, or transverse to, the first rotation axis of the transferassembly. The second angular velocity of the head may be different thanor the same as the first angular velocity of the head.

In an instance, the discrete articles may be transferred from thetransfer surface of the transfer member to the surface of the head on anoutput side of the transfer assembly. The method may comprise rotatingthe head about the second rotation axis at a third, different angularvelocity when the surface of the head is transferring the discretearticles to a discrete article conveying device, such as the secondmoving carrier member 106 or the linear conveyor 106′. A tangentialvelocity of the surface of the head may match, or substantially match, atangential velocity or linear speed of the discrete article conveyingdevice at a second point of discrete article transfer. The method maycomprise rotating the head about the second rotation axis between thefirst, second, and third angular velocities in one revolution of thehead.

The surface of the head may comprise an arcuate portion or may be fullyarcuate. The transfer surface may be flat, substantially flat, or maycomprise one or more flat portions. The transfer surface may also bearcuate or comprise one or more arcuate portions in some instances. Themethod may comprise moving the flat or substantially flat transfersurface radially inwardly and radially outwardly relative to the firstrotation axis of the transfer assembly at the point of discrete articletransfer to maintain the substantially constant minimum distance or gapbetween the surface of the head and the transfer surface. The transfersurface of the transfer member may also be rotated about a thirdrotation axis (e.g., rotation axis 164) between a first position and asecond position. The first rotation axis (e.g., rotation axis 132) ofthe transfer assembly may extend in a first direction and the thirdrotation axis of the transfer assembly may extend in a second, differentdirection. The first rotation axis of the transfer assembly may beparallel to, or substantially parallel to (e.g., +/−5 degrees), thesecond rotation axis (e.g., rotation axis 107) of the apparatus, and thethird rotation axis of the transfer assembly may be perpendicular to, orsubstantially perpendicular to (e.g., +/−5 degrees), the first andsecond rotation axes.

The transfer surface of the transfer assembly may be rotated betweenabout 80 degrees and about 100 degrees, about 90 degrees, or 90 degrees,about the third rotation axis of the transfer assembly between the firstposition and the second position. Other degrees of rotation between thefirst position and the second position are also specified herein, butnot again set forth here for brevity.

The method may further comprise using a radial displacement mechanismoperably engaged with a portion of the transfer member to maintain thetransfer surface at the substantially constant minimum distance awayfrom the surface of the head of the apparatus at the point or zone ofdiscrete article transfer. The method may also comprise maintaining asubstantially constant pressure between the transfer surface and thesurface of the head of the apparatus at the point or zone of discretearticle transfer.

In a form, a method of transferring discrete articles between a transferassembly and an apparatus comprising one or more heads is provided. Thetransfer assembly may comprise a frame defining a first rotation axisand at least one transfer member each comprising a transfer surfaceconfigured to receive one or more of the discrete articles. The methodmay comprise rotating the transfer member of the transfer assembly aboutthe first rotation axis at a constant, or substantially constant,angular velocity and maintaining the transfer surface at a constant, orsubstantially constant, minimum distance away from a surface of the headat a point or zone of discrete article transfer. A tangential velocityof the transfer surface may be constant or substantially constant at thepoint or zone of discrete article transfer. The method may furthercomprise rotating the head of the apparatus about a second rotation axisat a variable angular velocity. A first angular velocity of the head maybe constant, substantially constant, or variable, at the point or zoneof discrete article transfer. A tangential velocity of the surface ofthe head may be the same as, or substantially the same as (e.g., +/−2%),the constant, or substantially constant, tangential velocity of thetransfer surface at the point or zone of discrete article transfer. Thetangential velocity of the surface of the head, in other instances, maybe different than the constant, or substantially constant, tangentialvelocity of the transfer surface at the point or zone of discretearticle transfer.

The transfer surface may be flat, substantially flat, or may comprise aflat portion. In other instances, the transfer surface may be arcuate orcomprise one or more arcuate portions. The surface of the head maycomprise one or more arcuate portions or may be arcuate. The surface ofthe head may be configured to receive one of the discrete articles. Thefirst rotation axis of the transfer assembly may be parallel to, orsubstantially parallel to, the second rotation axis of the apparatus.The method may comprise rotating the transfer member about a thirdrotation axis of the transfer assembly between a first position and asecond position. The transfer member may be rotated between about 80degrees and about 100 degrees, about 90 degrees, or 90 degrees, aboutthe third rotation axis between the first position and the secondposition. Other degrees of rotation between the first and secondpositions are specified herein, but are not again set forth for brevity.The first rotation axis of the transfer assembly and the second rotationaxis of the apparatus may be perpendicular to, or substantiallyperpendicular to, the third rotation axis of the transfer assembly.

In a form, a method may comprise transferring discrete articles betweena transfer assembly and an apparatus comprising at least one head. Thetransfer assembly may comprise a frame defining a first rotation axisand at least one transfer member each comprising a transfer surfaceconfigured to receive one or more of the discrete articles. The transfersurface may be flat, substantially flat, or may comprise one or moreflat or substantially flat portions. In other instances, the transfersurface may be arcuate or may comprise one or more an arcuate portions.The method may comprise rotating the transfer member of the transferassembly about the first rotation axis at a constant, or substantiallyconstant, angular velocity, maintaining the transfer surface at aconstant, or substantially constant, minimum distance away from asurface of the head at a point or zone of discrete article transfer, androtating the head of the apparatus about a second rotation axis at avariable angular velocity. A first angular velocity of the head may beconstant, substantially constant, or variable at the point or zone ofdiscrete article transfer. The surface of the head may be arcuate or maycomprise an arcuate portion. The first rotation axis of the transferassembly may be parallel to, or substantially parallel to, the secondrotation axis of the apparatus. The method may comprise rotating thetransfer member about a third rotation axis of the transfer assemblybetween a first position and a second position. The first rotation ofthe transfer assembly axis may extend in a first direction. The thirdrotation axis of the transfer assembly may extend in a second, differentdirection. The transfer member may be rotated about the third rotationaxis between about 80 degrees and about 100, about 90 degrees, or 90degrees, between the first position and the second position. Otherdegrees increments between the first and second positions are specifiedherein, but not set forth again for brevity.

A first tangential velocity of the transfer surface of the transfermember may be constant, or substantially constant, at the point or zoneof discrete article transfer. A second tangentially velocity of thesurface of the head may be constant, substantially constant, or variableat the point or zone of discrete article transfer. The first and secondtangentially velocities may be the same, substantially the same, ordifferent at the point or zone of discrete article transfer.

In a form a method of transferring discrete articles from a transferassembly to an apparatus comprising one or more heads is provided. Thetransfer assembly may comprise a frame defining a first rotation axisand at least one transfer member each comprising a transfer surfaceconfigured to receive one of the discrete articles. The method maycomprise rotating the transfer member of the transfer assembly about thefirst rotation axis, maintaining the transfer surface at a substantiallyconstant minimum distance away from a surface of the head at a point orzone of discrete article transfer. The transfer surface of the transfermember may be moved at a first constant, or substantially constant,tangential velocity at the point or zone of discrete article transfer.The method may further comprise rotating the head of the apparatus abouta second rotation axis. The surface of the head may be moved at a secondconstant, or substantially constant, tangential velocity at the point orzone of discrete article transfer. The second constant, or substantiallyconstant, tangential velocity of the head may be greater than the firstconstant, or substantially constant, tangential velocity of the transfersurface at the point or zone of discrete article transfer to tension thediscrete articles being transferred. The second constant, orsubstantially constant, tangential velocity may be at least about 2% toabout 35%, at least about 2% to about 30%, at least about 5% to about25%, at least about 3% to about 25%, at least about 3%, at least about5%, at least about 10%, or at least about 15%, specifically reciting all0.1% increments within the specified ranges and all ranges formedtherein or thereby, greater than the first tangential velocity at thepoint or zone of discrete article transfer to tension the discretearticle being transferred.

The transfer member may be rotated about the first rotation axis of thetransfer assembly at a constant, or substantially constant, angularvelocity. The head may be rotated about the second rotation axis of theapparatus at a variable angular velocity. The rotating the head aboutthe second rotation axis step may comprise rotating the head about thesecond rotation axis between a first angular velocity, a second angularvelocity, and at least a third angular velocity, or between a pluralityof angular velocities, in one revolution of the head. The first, second,and third angular velocities may all be different. In other instances,at least one of the first, second, and third angular velocities may bedifferent than the other two angular velocities.

The transfer surface of the transfer member may be rotated about a thirdrotation axis of the transfer assembly between a first position and asecond position. The third rotation axis may not be parallel to thefirst rotation axis of the transfer assembly and, instead, may beperpendicular, or substantially perpendicular, to the first rotationaxis. The transfer surface may be rotated between about 80 degrees andabout 100 degrees, about 90 degrees, or 90 degrees, between the firstposition and the second position. Other degree increments between thefirst position and second position are described herein, but not setforth again for brevity.

The transfer surface may be flat, substantially flat, or may compriseone or more flat portions. The transfer surface may also be arcuate, inother instances. The surface of the head may be arcuate or may compriseone or more arcuate portions. The method may comprise moving the flat orsubstantially flat transfer surface radially inwardly and radiallyoutwardly relative to the first rotation axis of the transfer assemblyat the point or zone of discrete article transfer to maintain thesubstantially constant minimum distance. The method may comprise using aradial displacement mechanism operably engaged with a portion of thetransfer member to maintain the transfer surface at the constant, orsubstantially constant, minimum distance away from the surface of thehead of the apparatus at the point or zone of discrete article transfer.The method may also comprise maintaining a constant, or substantiallyconstant, pressure between the transfer surface of the transfer memberand the surface of the head of the apparatus at the point or zone ofdiscrete article transfer.

In a form, a method of transferring discrete articles from a transferassembly to an apparatus comprising one or more heads is provided. Thetransfer assembly may comprise a frame defining a first rotation axisand at least one transfer member each comprising a transfer surfaceconfigured to receive one or more of the discrete articles. The methodmay comprise rotating the transfer member of the transfer assembly aboutthe first rotation axis of the transfer assembly at a constant, orsubstantially constant, angular velocity and maintaining the transfersurface at a constant, or substantially constant, minimum distance awayfrom a surface of the head at a point or zone of discrete articletransfer. The transfer surface may be moved at a first constant, orsubstantially constant, tangential velocity at the point or zone ofdiscrete article transfer. The method may comprise rotating the head ofthe apparatus about a second rotation axis at a variable angularvelocity or at a plurality of angular velocities. The surface of thehead may be moved at a second constant, or substantially constant,tangential velocity at the point or zone of discrete article transfer.The second constant, or substantially constant, tangential velocity ofthe head may be greater than the first constant, or substantiallyconstant, tangential velocity of the transfer surface at the point orzone of discrete article transfer to tension the discrete article beingtransferred. The second constant, or substantially constant, tangentialvelocity may be at least about 2% to about 35%, at least about 2% toabout 30%, at least about 5% to about 25%, at least about 3% to about25%, at least about 3%, at least about 5%, at least about 10%, or atleast about 15%, specifically reciting all 0.1% increments within thespecified ranges and all ranges formed therein or thereby, greater thanthe first constant, or substantially constant, tangential velocity atthe point or zone of discrete article transfer to tension the discretearticle being transferred.

The rotating of the head of the apparatus step may comprise rotating thehead about the rotation axis of the apparatus between a first angularvelocity, a second angular velocity, and a third angular velocity, orbetween a plurality of angular velocities, in one revolution of thehead. The first, second, and third angular velocities may all bedifferent. In other instances, at least one of the first, second, andthird angular velocities may be different than the other two.

The transfer surface may be flat, substantially flat, or may compriseone or more flat portions. In other instances, the transfer surface maybe arcuate or comprise one or more arcuate portions. The surface of thehead may be arcuate or may comprise one or more arcuate portions.

The method may further comprise moving the flat or substantially flattransfer surface radially inwardly and radially outwardly relative tothe first rotation axis of the transfer assembly at the point or zone ofdiscrete article transfer to maintain the constant, or substantiallyconstant, minimum distance. The method may also comprise using a radialdisplacement mechanism operably engaged with a portion of the transfermember to maintain the transfer surface at the constant, orsubstantially constant, minimum distance away from the surface of thehead of the apparatus at the point or zone of discrete article transfer.The method may additionally comprise maintaining a constant, orsubstantially constant, pressure between the transfer surface and thesurface of the head of the apparatus at the point or zone of discretearticle transfer.

In a form, a method of transferring discrete articles from a transferassembly to an apparatus comprising one or more heads is provided. Thetransfer assembly may comprise a frame defining a first rotation axisand one or more transfer members each comprising a transfer surfaceconfigured to receive one or more of the discrete articles. The transfersurface may be flat, substantially flat, or may comprise one or moreflat portions. The transfer surface may also be arcuate, or comprisearcuate portions, in some instances. The method may comprise rotatingthe transfer member of the transfer assembly about the first rotationaxis and maintaining the transfer surface at a constant, orsubstantially constant, minimum distance away from a surface of the headat a point or zone of discrete article transfer. The transfer surfacemay be moved at a first constant, or substantially constant, tangentialvelocity at the point or zone of discrete article transfer. The methodmay comprise rotating the head of the apparatus about a second rotationaxis. The surface of the head may be moved at a second constant, orsubstantially constant, tangential velocity at the point or zone ofdiscrete article transfer. The surface of the head, in other instances,may also be moved at a variable tangential velocity at the point or zoneof discrete article transfer. The second constant, or substantiallyconstant, tangential velocity of the head may be greater than the firstconstant, or substantially constant, tangential velocity of the transfersurface at the point or zone of discrete article transfer to tension thediscrete articles being transferred.

In all of the methods described herein, the methods may compriseretaining one or more of the discrete articles to the transfer surfacesor to the surfaces of the heads through fluid pressures, static,magnetic, adhesives, and/or adhesive attraction, for example.

The transfer members, apparatuses comprising the heads, wheels, rotationassemblies, and/or any other part or component that rotates about arotation axis may comprise aluminum, steel, plastic, titanium, carbonfiber composite, and/or other high strength/light weight material. Byusing high strength/light weight materials, the amount of mass rotatingabout a rotation axis may be reduced compared to related art transferassemblies or apparatuses. This reduction in mass may allow the overalltransfer apparatuses of the present disclosure to operate at a higherthroughput of discrete articles per minute.

The overall transfer apparatuses of the present disclosure may processor transfer over 800 discrete articles per minute, alternatively, over900 discrete articles per minute, alternatively, over 1,000 discretearticles per minute, alternatively, over 1,100 discrete articles perminute, alternatively, over 1,200 discrete articles per minute, andalternatively, over 1,300 discrete articles per minute. In otherinstances, the overall transfer apparatuses of the present disclosuremay process or transfer between 600 and 1500 discrete articles perminute, specifically including each whole number within the specifiedrange.

Any of the methods and apparatuses described herein may be used inconjunction with the inventive concepts disclosed in European PatentApplication No. EP12162251.8, entitled METHOD AND APPARATUS FOR MAKINGPERSONAL HYGIENE ABSORBENT ARTICLES, and filed on Mar. 29, 2012.

Any of the transfer surfaces (e.g., 136), carrier members (e.g., 104,106), and/or the heads (e.g., heads 105, 105′) may comprise one or moreresilient materials thereon. The resilient materials may comprise one ormore foams, rubbers, silicon rubbers, polymers, and/or polyurethane. Theresilient materials may cover the entire surfaces of the transfersurfaces, the carrier members, and/or the heads, or may cover less thanthe entire surfaces of the transfer surfaces, the carrier members,and/or the heads. The resilient members may be provided to achievebetter transfer of discrete articles by allowing one component to applya force to another component during transfer. Stated another way, theresilient members may be provided to allow for interference transferbetween at least some of the various components discussed in thisparagraph. In some forms, the resilient members may have a Shore Ahardness of between about 20 and about 80, specifically reciting all 0.5Shore A hardness increments within the specified range.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications may be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A method of transferring discrete articlesbetween a transfer assembly and an apparatus comprising a head, whereinthe transfer assembly comprises a frame defining a first rotation axisand a transfer member comprising a transfer surface configured toreceive one of the discrete articles, the method comprising: rotatingthe transfer member of the transfer assembly about the first rotationaxis at a substantially constant angular velocity; maintaining thetransfer surface at a substantially constant minimum distance away froma surface of the head at a point of discrete article transfer; androtating the head of the apparatus about a second rotation axis at aplurality of angular velocities, wherein a first angular velocity of thehead is substantially constant at the point of discrete articletransfer.
 2. The method of claim 1, wherein a tangential velocity of thetransfer surface is substantially constant at the point of discretearticle transfer.
 3. The method of claim 2, wherein a tangentialvelocity of the surface of the head is substantially the same as thesubstantially constant tangential velocity of the transfer surface atthe point of discrete article transfer.
 4. The method of claim 3,comprising rotating the head about the second rotation axis at a secondangular velocity when the head is outside of a zone of discrete articletransfer, wherein the second angular velocity is different than thefirst angular velocity.
 5. The method of claim 4, wherein the discretearticles are transferred from the transfer surface to the surface of thehead, the method comprising rotating the head about the second rotationaxis at a third, different angular velocity when the surface of the headis transferring the discrete articles to a discrete article conveyingdevice, and wherein a second tangential velocity of the surface of thehead substantially matches a tangential velocity or linear speed of thediscrete article conveying device at a second point of discrete articletransfer.
 6. The method of claim 5, comprising rotating the head aboutthe second rotation axis between the first, second, and third angularvelocities in one revolution of the head.
 7. The method of claim 1,wherein the surface of the head comprises an arcuate portion, andwherein the transfer surface is substantially flat.
 8. The method ofclaim 1, wherein the discrete articles are transferred from the transfersurface of the transfer assembly to the surface of the head of theapparatus.
 9. The method of claim 1, wherein the discrete articles aretransferred from the surface of the head of the apparatus to thetransfer surface of the transfer assembly.
 10. The method of claim 1,wherein the transfer surface is a substantially flat transfer surface,the method comprising moving the substantially flat transfer surfaceradially inwardly and radially outwardly relative to the first rotationaxis at the point of discrete article transfer to maintain thesubstantially constant minimum distance.
 11. The method of claim 1,comprising rotating the transfer surface about a third rotation axisbetween a first position and a second position, wherein the firstrotation axis extends in a first direction, and wherein the thirdrotation axis extends in a second, different direction.
 12. The methodof claim 11, wherein the first rotation axis is substantially parallelto the second rotation axis, and wherein the third rotation axis issubstantially perpendicular to the first and second rotation axes. 13.The method of claim 11, wherein the transfer surface is rotated betweenabout 80 degrees and about 100 degrees about the third rotation axisbetween the first position and the second position.
 14. The method ofclaim 1, comprising using a radial displacement mechanism operablyengaged with a portion of the transfer member to maintain the transfersurface at the substantially constant minimum distance away from thesurface of the head of the apparatus at the point of discrete articletransfer.
 15. The method of claim 1, comprising maintaining asubstantially constant pressure between the transfer surface and thesurface of the head of the apparatus at the point of discrete articletransfer.
 16. A method of transferring discrete articles between atransfer assembly and an apparatus comprising a head, wherein thetransfer assembly comprises a frame defining a first rotation axis and atransfer member comprising a transfer surface configured to receive oneof the discrete articles, the method comprising: rotating the transfermember of the transfer assembly about the first rotation axis at asubstantially constant angular velocity; maintaining the transfersurface at a substantially constant minimum distance away from a surfaceof the head at a point of discrete article transfer, wherein atangential velocity of the transfer surface is substantially constant atthe point of discrete article transfer; and rotating the head of theapparatus about a second rotation axis at a variable angular velocity,wherein a first angular velocity of the head is substantially constantat the point of discrete article transfer, and wherein a tangentialvelocity of the surface of the head is substantially the same as thesubstantially constant tangential velocity of the transfer surface atthe point of discrete article transfer.
 17. The method of claim 16,wherein the transfer surface is substantially flat, wherein the surfaceof the head comprises an arcuate portion, and wherein the surface of thehead is configured to receive one of the discrete articles.
 18. Themethod of claim 16, wherein the first rotation axis is substantiallyparallel to the second rotation axis, the method comprising rotating thetransfer member about a third rotation axis between a first position anda second position, wherein the transfer member is rotated between about80 degrees and about 100 degrees about the third rotation axis betweenthe first position and the second position, and wherein the firstrotation axis is substantially perpendicular to the third rotation axis.19. A method of transferring discrete articles between a transferassembly and an apparatus comprising a head, wherein the transferassembly comprises a frame defining a first rotation axis and a transfermember comprising a transfer surface configured to receive one of thediscrete articles, wherein the transfer surface is substantially flat,the method comprising: rotating the transfer member of the transferassembly about the first rotation axis at a substantially constantangular velocity; maintaining the transfer surface at a substantiallyconstant minimum distance away from a surface of the head in a zone ofdiscrete article transfer; and rotating the head of the apparatus abouta second rotation axis at a variable angular velocity.
 20. The method ofclaim 19, wherein a first angular velocity of the head is substantiallyconstant in the zone of discrete article transfer, and wherein thesurface of the head is arcuate.
 21. The method of claim 19, wherein thefirst rotation axis is substantially parallel to the second rotationaxis.
 22. The method of claim 19, comprising rotating the transfermember about a third rotation axis between a first position and a secondposition, wherein the first rotation axis extends in a first direction,wherein the third rotation axis extends in a second, differentdirection, and wherein the transfer member is rotated about the thirdrotation axis between about 80 degrees and about 100 degrees between thefirst position and the second position.
 23. The method of claim 19,wherein a first tangential velocity of the transfer surface issubstantially constant in the zone of discrete article transfer, whereina second tangentially velocity of the surface of the head issubstantially constant in the zone of discrete article transfer, andwherein the first and second tangentially velocities are substantiallythe same in the zone of discrete article transfer.
 24. The method ofclaim 19, wherein the transfer surface or a surface of the headcomprises a resilient material.
 25. A method of transferring discretearticles between a transfer assembly and an apparatus comprising a head,wherein the transfer assembly comprises a frame defining a firstrotation axis and a transfer member comprising a transfer surfaceconfigured to receive one of the discrete articles, the methodcomprising: rotating the transfer member of the transfer assembly aboutthe first rotation axis at a substantially constant angular velocity;maintaining the transfer surface at a substantially constant minimumdistance away from a surface of the head at a point of discrete articletransfer, wherein the transfer surface is a substantially flat transfersurface; moving the substantially flat transfer surface radiallyinwardly and radially outwardly relative to the first rotation axis atthe point of discrete article transfer to maintain the substantiallyconstant minimum distance; and rotating the head of the apparatus abouta second rotation axis at a plurality of angular velocities, wherein afirst angular velocity of the head is substantially constant at thepoint of discrete article transfer.
 26. A method of transferringdiscrete articles between a transfer assembly and an apparatuscomprising a head, wherein the transfer assembly comprises a framedefining a first rotation axis and a transfer member comprising atransfer surface configured to receive one of the discrete articles, themethod comprising: rotating the transfer member of the transfer assemblyabout the first rotation axis at a substantially constant angularvelocity; maintaining the transfer surface at a substantially constantminimum distance away from a surface of the head at a point of discretearticle transfer; moving the transfer surface radially inwardly andradially outwardly relative to the first rotation axis at the point ofdiscrete article transfer to maintain the substantially constant minimumdistance; and rotating the head of the apparatus about a second rotationaxis at a plurality of angular velocities, wherein a first angularvelocity of the head is substantially constant at the point of discretearticle transfer.